QUALITY CONTROL

CONSTRUCTION ASPECTS
MANUAL
VOLUME-II

FOREWORD

IRRIGATION & CAD DEPARTMENT i

TELANGANA STATE
 INDEX

VOLUME II- QUALITY CONTROL – CONSTRUCTION

ASPECTS MANUAL

S. PAGE
CHAPTER NO. DESCRIPTION
NO. NO.

1.1 Earth Work 1

1.2 Concrete 8

1.3 Preparation of Subgrade for CC Lining 31

1.4 CC Lining 38

1 PART-I 1.5 Shotcreting & Guniting 46

1.6 Tunneling 54

1.7 Grouting 59

1.8 Barrages 74

1.9 Pressure Mains 89

2.1 List Of Registers To Be Maintained At The

115
Site

2.2 O.K. Cards 117

2.3 Details Of Tests to Be Conducted Before the

Work, During The Work & After The Work & 118
List Of Lab Equipment
PART-II
2 2.4 Frequency Of Testing 151

2.5 List Of Equipment for Works Costing Less

159
Than 2 Crore

2.6 List Of Equipment for Works Costing More

161
Than 2 Crores

2.7 Monitoring Through Quality Control Charts 165

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 2.8 Compilation Of Quality Control Data 175

2.9 Usage Of Manufactured Sand 176

2.10 Geosynthetics 177

ANNEXURES
IN-SITU PERMEABILITY BY JAPANESE
1. ANNEXURE – I 187
METHOD
SKETCH SHOWING CONSTRUCTION
2. ANNEXURE – II 189
JOINTS IN LINING
ANNEXURE – III ILLUSTRATIVE SKETCH SHOWING
3. TREATMENT OF CANAL PRISM IN 190
EXPANSIVE SOILS WITH CNS MATERIAL
ANNEXURE – IV DATA OF THE CORES TAKEN FROM IN
4. 192
SITU CONCRETE CANAL LINING
ANNEXURE – V PLATE -1A, 2A, 3A,1B, 2B, 3B CONTROL
5. CHARTS FOR CONCRETE STRENGTHS & 193
CEMENT STRENGTHS
ANNEXURE – VI IMPORTANT CIRCULAR's, GO's, MEMO's –
6. 196
QUALITY ASPECTS
ANNEXURE – VII
7. O.K CARDS FORMATS 199

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 PART-I

GENERAL EXECUTION PROCEDURES

AND SPECIFICATIONS

iv
1. EARTHWORK

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 1. EARTH WORK
(IS CODES, 2720, 4701, 8237, 9451, 1200)
1.0 EXCAVATION OF CANALS
PROCEDURE FOR EXECUTING EARTHWORK:
(A) General:
i) Sufficient number of reference Bench marks (DCBM) for facilitating setting out works
and taking levels shall be established.
ii) Permanent reference lines and check profiles at suitable intervals for checking the
execution of all slopes, steps and elevation of the profiles of the approved drawings,
shall be established.
iii) The entire area required for setting out, shall be cleared of all tree stumps, roots, bush
wood, rubbish of all kinds, loose and all objectionable materials.
(B) Stripping:
i) The work area shall be stripped of the surface soil, including vegetation, overlying
grass, organic matter, bushes, roots and other perishable or unsuitable material before
commencing of the excavation. It shall be done as per the requirement or to a
maximum depth of 0.30 m or as specified or as directed by the Engineer-in-charge.
ii) Prior to starting the stripping, initial cross-sections shall be taken at suitable interval
of 25 m, or as specified or as directed by Engineer-in-charge and shall be recorded in
ink directly in the field books.
iii) After the work of stripping in the canal width is completed, detailed cross sections
shall be taken as specified or as directed by Engineer-in-charge to form the base for
computing the quantities of excavation or embankments.
(C) Borrow Area:
i) In case when the materials required for construction of different zones of embankment
and backfill around the structures are not available from canal excavation foundation
excavation, the same are to be obtained from the approved borrow area, designated
within the reasonable lead or as directed by the Engineer in charge.
ii) Borrow pits, along the canal shall be operated in special case only after due approval
of the competent authority keeping in view the hydraulic gradient line. This should not
impair the usefulness of soil; the appearance of any part of work or any other property.

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iii) Need a certificate for approval of borrow material source for soil to be used in
Embankment/ Subgrade and the properties of soils are entered in the requisite field
register and the same soil may be stored for future reference.
iv) The stripping of borrow areas shall be done as per "B (i)" above.
v) Necessary grid lines with base line at suitable intervals shall be marked prior to and
after stripping to take the levels of the cross-sections to compute the quantity of
stripping and the materials borrowed from the borrow area.
vi) Necessary sample from the different depth shall be collected and got tested for their
suitability in different zones of embankment/ backfill prior to commencing the borrow
area.
vii) The required moisture as determined by the laboratory test shall be introduced in to
the borrow area itself, by watering well in advance of the excavation to ensure
uniformity of moisture content.
viii) Moisture control register shall be maintained looking to the day to day initial moisture
content of borrow area's material and the optimum moisture content of the respective
material obtained from proctor tests.
ix) The depth of cut in all borrow areas and borrow pits shall be designated by the Engineer-
in- charge. Each borrow area shall be fully exploited to avoid haphazard exploitation.
The borrow area excavation shall be carried out in such a way so as to produce the
required uniformity mixture of materials for the embankment with the available
excavation machinery.
DOS DO NOT’S
1. Fixup the centre line and set the curves 1. Do not avoid approval of the deviation
correctly. statement.
2. Take working levels, real variation in 2. Avoid over break and loosening of
ground levels and classification of soils as canal.
per Govt. Memo No. 1970-12/72-11, dated
4-7-1994.
3. Get top soil vegetation etc., removed. 3. Do not mix up useful soils with other
4. Provide treatment with C.N.S. soils in B.C. soil of cutting.
reaches (Expansive soils) 4. Unsighty heaps should be avoided.

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 5. Form spoil bank as per drawing and away
from side drain with suitable gaps for
drainage into the valley.
6. Form Dowel Bank, as per drawing.
7. Form Inspection path to a uniform
longitudinal gradient and with gentle
transverse slope towards toe drains.
8. Compact over excavation/breakage portion
with suitable soils, gravel, spalls.

1.2 FORMATION OF EMBANKMENTS:

(D) Embankment:
(IS: 4701:1982) (IS: 14690:1999) (IS: 2720: Part 33: 1971)
@nvv

i) This may be in the reaches of canals in partial cutting and partial banking or in full
banking with or without bed banking.
ii) Before commencement of the work, it shall be ensured that the materials for different
zones of approved section, based on laboratory tests are available.
iii) Stripped ground shall be scarified and loosened by using plough or ripper.
iv) The base-seat for embankment to receive earth shall be watered to the required
moisture content and shall be compacted with suitable type of compactor so as to attain
98% compaction or as specified.
v) The layers for the embankment portion shall be placed continuously and
approximately in horizontal loose layers of thickness as per the agreement conditions
and IS codes in depth, in the respective zone, to the full width of the embankments,
including slopes at the respective level, if it is mentioned in the agreement
categorically otherwise the loose layer thickness shall be as per the approved test
sections and to get required compaction efficiency. However, the loose layer thickness
shall be less than 30 cm or as per the agreement conditions and IS codes. This thickness
is irrespective of soil type and compactors etc., for canal or earth dam embankment
works.
vi) Construction of embankment shall begin at toe of the fill and in no case, material shall
be dumped from the top, to widen the embankment.
vii) Adequate Proud Section not less than 20 cm in thickness measured perpendicular to
the slope or as specified shall be provided on canal lining side and outer side.

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viii) Each layer shall be tested for Field Dry Density (FDD) and Field Moisture Content
(FMC) as per the frequency stipulated in the tender specifications.
ix) No fresh layer shall be laid until the previous layer is properly watered & compacted
as per requirement.
x) For proper bond of the embankment done in the previous season with new
embankment, care shall be taken as under:
a. In case of the bank to be extended horizontally, it shall be cut to a longitudinal slope
not steeper than 1 in 5 and the benching is to be with 0.6 m width tread in staggered to
accommodate roller width and necessary watering shall be done, after all loose
material is removed.
b. If the old bank is to be raised vertically, vegetation shall be cleared followed by
scarifying, watering and placing of new earth layer as specified above.
c. The rain cuts, if any, shall be made good with due care by filling with proper / selected
soil duly watered and compacted with suitable compactors or tampers.

(E) Important Features:

i) Laboratory testing of soil to be used shall be done well in advance.

ii) Borrow areas to be identified looking to the suitability of soil available for different
zones of the embankment.
iii) Water content control to be exercised rigorously either by borrow area watering or
spreading it uniformly over loose layer before rolling.
iv) Proper roller should be selected for compaction, with the help of field compaction
trial and the type of soil e.g. pad foot / sheep foot roller for cohesive soil, vibratory /
random roller for cohesion less soil and OMC of the soil is to be used for compaction
can be determined.
v) Thickness of loose layer shall be controlled for the embankment works are as follows:
(a) For all types of compaction equipment, the loose layer shall be of 22.5 cm (9”)
thick or as per agreement. However loose layer thickness shall be based on test section
and in any case shall not be more than 0.30 m thick irrespective type of roller and type
of soil.
(b) For Coarse Grained soils, by vibratory roller compaction, the loose layer
thickness can be 0.375 m. However, we don’t use these types of soils for embankment
construction of irrigation works.

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vi) Regular tests for field permeability, shear tests, field density and moisture control etc.
shall be conducted as per provisions/ codes.
vii) No fresh layer shall be laid until the previous layer is properly watered and compacted
as per requirement and tests are passed and recorded.
viii) In case of works with cohesion less soil, where compaction test for MDD/OMC is not
feasible, it shall be compacted to at least 70% of Relative Density (RD) or as directed
by the Engineer -in -charge. When the filters are provided, the filter material to be used
shall be checked for gradation curves and filter criteria shall be worked out and verified
as per clause 5.1.3 of IS 8237-1985. Compaction shall be done as specified.
DOS DO NOT’S
1. Get the top spoil, vegetation and sand 1. Do not raise the bank in piecemeal
patches removed to complete depth.
2. Scarify the ground and wet properly. 2. Do not allow new layer without
scarification and wetting of old
3. Obtain P.D. OMC for the useful soils layer.
and borrow soils. 3. Do not allow new layer unless
required degree of compaction is
4. Provide C.O.T.s according to height of achieved.
bank. 4. Don’t leave any loose layer unrolled
5. Raise embankment to full width with at the end of the day in rainy season.
uniform horizontal loose layer of 22.5 5. Don’t allow compacted layer to be
cm thickness or as per the approved more than approved test section.
test section/agreement.
6. Break clods, remove roots, big
boulders other materials etc., larger 6. No new layer to be laid unless the
than 80 mm from the soils used in over moisture layer is either
embankment. completely removed or allowed to
7. Supplement deficit moisture dry.
whenever required. 7. Don’t dump soils in heaps.
8. Provide 0.45 Mtr. extra offset on both
sides of bank. 8. Don’t dump the soils in water and
9. Compaction with 8 to 10 tons power slush.
roller/vibratory roller/sheep foot roller 9. Do not forget to provide settlement
as the case may be.Roller passes shall allowance of 2.5cm/mtr. Height of
be as per the field trial tests to achieve bank for power roller compaction.
required degree of compaction. 10. Don’t use expansive soils in
banking.
10. Sheep foot roller compaction is
mandatory for expansive soils,
required in COT and hearting zones.
11. Conduct field compaction tests and
determine compaction efficiency.
12. Check embankment profiles
periodically.

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 13. Ensure 8 minimum No. of passes or
no. of passes as per the field trial tests.
14. Provide 10% allowance in setting
profile of the embankment or as per
the agreement condition.
15. Ploughing/ Scarification to be formed
over old layer for proper bonding with
the new layer.
16. Conduct In-Situ Permeability Test
using Japanese method to assess the
‘K’ value. Further the permeability
shall also be verified by extracting
U.D samples at various zones.
Annexure-I

Records to be maintained:
i) Date of Earth work as indicated in Design note and drawing of embankment
section,
ii) Record of properties of soil available from canal excavation and Borrow area,
iii) Confirmatory tests of soil being used for embankment (during construction),
iv) Compaction test results of each layer and base seat of embankment,
v) Data for proctor test for each type of material used,
vi) Moisture control (before spreading @ NMC comparison with OMC,
vii) Layer wise Reduced Level Location etc.,
viii) Daily & Monthly Progress report,
ix) Record for filter material used shall be maintained such as Filter criteria,
Gradation Curve, Compaction / Watering etc., and
x) Check the borrow area.

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2. CONCRETE

8
 1.2 CONCRETE
(IS CODES 269, 383, 456, 516, 800, 1199, 2116, 2386, 3873, 4926, 9103, 10262, 14687)
1.2.0 PROCEDURE FOR EXECUTING R.C.C. WORK & CONCRETE FOR
STRUCTURES
(I) General:
i) Necessary TBM (DCBM), Reference line etc. shall be maintained and kept
undisturbed till completion of the structure.
ii) The foundation or the concrete- surface of the structures shall have to be
cleared of the objectionable matter before putting the concrete and shall be
got approved from competent authority.
iii) O.K. Card for placement of concrete shall be maintained.
iv) In case of earth foundation, all soft, loose mud and surface debris shall be
scrapped and removed.
v) The dry surface shall be moistened to a depth of about 15 cm to prevent
absorption of water from the fresh concrete.
vi) In case of old concrete surface, the surface shall be clean, rough and damp
when receiving the next lift by scrapping, chipping or by other suitable means.
vii) Proper anchoring rods should be provided where ever necessary.
(II) Materials:
A) Cement:
i) Ordinary Portland cement (OPC) conforming to relevant IS according to different
grades shall be used, in case of foundation concrete or other mass concrete works.
ii) PPC may be used if permitted.
iii) Samples from the stock of cement shall be collected in accordance with IS procedures
and shall be got tested well in advance as per the frequency specified.
iv) Cement older than 90 days shall not be used without retesting & prior approval of
Engineer-in-Charge.
B) Fine Aggregates:
i) Sand to be used shall be brought from the approved river shoal or manufactured sand
from crusher approved by ISO/NAC/NCC only. It shall confirm to the requirement of
IS: 383-2016 and other relevant specifications.
ii) Sand should be tested for Fineness Modulus (F. M.), Gradation, Specific Gravity.

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C) Coarse Aggregates:
i) Coarse aggregate for concrete shall be clean, hard, dense and free from all type of
vegetation. It shall be conforming to IS: 383-2016. Predominantly flaky and elongated
aggregate shall not be used. Gravel/ metal shall be brought from only approved quarry
and shall be tested for their gradation; specific gravity, water absorption, impact and
abrasion values, soundness, Petro-graphic analysis, flakiness and elongation.
ii) Each grade of material ranging from 40 mm to 4.75 mm shall be stacked separately.
D) Water: Potable water free from any other deleterious or organic material shall be used.
E) Reinforcing Steel:
i. H.Y.S.D. bars and M.S. bars or other structural steel confirming to relevant IS codes
shall be used as reinforcement.
ii. Samples of such bars shall be collected and tested before their use as per the frequency
specified in the relevant specifications.
iii. Check the consignment report of steel used at the site.
iv. The brand of steel mentioned in the agreement should be approved by the Board of
Chief Engineers (BOCE) and the steel shall conform to the requirements of IS 800:
2007, and IS 1786: 2008.

(III) Manufacturing of Cement Concrete:

i) The concrete mix shall be got designed in laboratory for various grades i.e., M15, M20
& other grade as specified. Use proposed construction materials to achieve the
required workability& strength at optimum cement level.
ii) For RCC works, minimum grade of concrete shall be M20.
iii) The prescribed amount of different materials such as coarse aggregate, fine aggregate,
water, cement and AEA (Air Entraining Agent) shall be as per the mix design,
Batching plant or weigh batches shall operate within the limits of accuracy specified.
They shall be calibrated regularly to keep the combined inaccuracies in feeding and
measuring the material, water and cement within the specified limit.
iv) The concrete ingredients thus measured and fed shall be mixed thoroughly in batch
mixers for the prescribed time of mixing so as to uniform distribution of all the
constituent material resulting in dense, plastic, stiff concrete of uniform colour and
consistency.

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(IV) Transporting, Placing & Compaction of concrete:
i) Concrete shall be transported from the mixing plant to the placement position as
rapidly as possible, by use of transit mixer or suitable placers, conveyors etc.
ii) In case when chutes are used for concrete conveying, they shall be of such size and
shape as to ensure a steady uniform flow of concrete without segregation.
iii) Before placing of concrete, foundation surface or surface of old, concrete shall be
cleaned, roughened and damped.
iv) Concrete, as far as practicable, shall be placed directly in final position, and shall not
be caused to flow to avoid segregation.
v) In case of old concrete surface, it should be cleaned and chipping/ cutting shall be
attempted as per requirement. Clearing with wire brush / roughening of surface shall
be done invariably.
vi) Proper Green cutting/Shear Block has to be ensured before laying next layer of
concrete for better bonding strength for old concrete surface.
vii) Hand placing of concrete shall not be permitted and it should always be insisted for
providing suitable means to convey the concrete to avoid free fall from unacceptable
height or angle.
viii) Cold joints shall be avoided. However, in unavoidable circumstances, if a cold joint is
formed then necessary remedial measures and contraction joint treatment shall be done
prior to resuming the placement of concrete.
ix) Concrete placed shall be concreted in final position within specified time. Re-tamping
of concrete shall not be permitted.
x) Concrete shall be compacted with the help of suitable type of vibrators, (Normally it
shall be immersion type having vibrating head of 100 mm, operated at speed of at least
6000 vibrations per minutes when immersed in the concrete). It shall be compacted to
achieve the desired density.
xi) The surfaces of the concrete vibrated and finished shall be even, smooth and free from
pockets, projections, honey-combing and other objectionable defects.

(V) Form Work:

i) Formwork to be used to confine the concrete for bringing shape and required lines shall
preferably be of steel and got approved from the Engineer-in-charge. Effective and

11
 sufficient number of props and bracing shall be provided to prevent deformation due
to placing, vibrating and compacting concrete.
ii) The surface of formwork shall be such as to produce surface finishes as specified and
form work joints tight enough i.e. grout tight.
iii) Before fixing the formwork in line and level, it shall be properly cleaned and oiled.
iv) Formwork fixed in position duly lines and levelled shall be inspected prior to
commencing of concrete and O.K. card shall be maintained.
a) Embedded parts shall be fixed in position with desired standard of
Geometry.
b) PVC water stops shall be fixed in position so as to have its bulb in the
centre of joint.
c) It shall confirm to IS 15058-2002 and a typical cross–section of PVC
Water- Stop is shown below.

All dimensions in millimetre

Typical cross- section of PVC Water- Stop
v) Formwork shall be removed as soon as the concrete has hardened sufficiently or
looking to the requirement of design. Due care shall be taken at the time of removal,
so as to avoid damage to concrete.
vi) Formed surfaces shall have finish F1, F2, F3, or F4 as specified in the relevant
specification. Similarly unformed surfaces, i.e., U1, U2, U3 and finish U4 shall be in
conformity with relevant specifications. If concrete is to be repaired then the repair of
concrete shall be attended immediately as per the provisions contained in the relevant
specifications.
vii)The form work shall confirm to IS 14687-1999 (Guidelines for false work concrete
structures).
(VI) Curing of Concrete:
(A) Moist Curing:

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 i) Top surfaces of concrete shall be kept moistened by covering with hessian
cloth or wet jute bags or by sprinkling water or by any other effective
means as per agreement conditions.
ii) Steep slopes/vertical surfaces shall be kept completely and continuously
moist by water.
iii) Concrete shall be cured with water for 28 days.
(B) Membrane Curing:
i) Membrane curing shall be done by application of suitable approved white
pigmented type curing compound. (As per the discretion of Engineer-in-
Charge)
ii) When curing compound is to be used, application shall commence
immediately after the finishing operations are completed. It shall be applied
with mechanical spray pump of insecticide or Jumbo mounted on Work
Bridge. Timely application of curing compound yields good results.
iii) Curing compound to be used shall be of approved quality and shall be got
tested for water retention and reluctance test, well in advance.
iv) Record for test results of consumption, reflectance and area covered by
curing compound shall be maintained, for this the O.K. card is evolved.

1.2.1 SPECIFICATIONS OF PLAIN AND REINFORCED CONCRETE

1.2.1.1. Proportioning & batching:
Design mix concrete (controlled concrete) shall be used for concrete of grade M15 and
higher. As per IS 456, the Nominal mix concrete may be used for concrete up to M20 or
lower mix. Nominal mixes may be used with the permission of Engineer-in-charge.
which,however. is likely to involve a higher cement content with accordance to Clause
9.1.1 of IS 456-2000.
In proportioning concrete, the quantity of both cement and aggregate shall be determined
by mass. Water shall be either measured by volume in calibrated tanks or weighed.
Concrete shall be manufactured either in batching mixing plants/self loading mixer or
mechanical mixers of various capacities (14/10 or 10/7). Alternatively, mobile self-loading
weight batching-mixing and transporting mixers of suitable drum capacity can be used,
both for mixing and transporting concrete. The mix proportions shall be such as to ensure

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 the workability of the fresh concrete and when concrete is hardened, it shall have the
required strength, durability, and surface finish.
Proportions for Nominal Mix Concrete as per IS 456 :2000 Reaffirmed 2021
Proportions for Nominal Mix Concrete

Total quantity of dry

aggregates by
Proportion of fine
mass per 50 kg of cement
Grade of aggregate to coarse
to be taken as
Concrete aggregate (by mass)
the sum of the individual
masses of fine
and coarse aggregate
(kg)
(1) (2) (3)
M15 330 Generally 1:2 but
subject to an upper
M20 250 limit of 1:1.5 and a
lower limit of 1:2.5

Notes:
i) Graded aggregates shall be used.
ii) Water cement ratio should be as per mix design.

1.2.1.2. Design Mix concrete (IS: 10262 -2019):

The mix shall be designed to produce the grade of concrete having the required
workability and characteristics strength not less than appropriate values given below:

Specified characteristic
Grade of Designation of
compressive Strength of 150
concrete
mm cube at 28 days in N/mm2

M15 15
M20 20
M25 25

The concrete mix shall be designed for the 'target mean strength'. The target mean
strength of concrete mix should be equal to characteristic strength plus 1.65 times the
standard deviation.
f’ck = fck + 1.65 S
or
f’ck = fck + X

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 whichever is higher.
Where
f’ck = target mean compressive strength at 28 days in N/mm2,
fck = characteristic compressive strength at 28 days in N/mm2,
S = standard deviation in N/mm2 and
X = factor based on the grade of concrete as per table below

Where sufficient test results for a particular grade of concrete are not available, the
value of standard deviation given below shall be assumed for design mix of concrete in the
first instance. As soon as the results of samples are available, actual standard deviation
shall be calculated and the mix designed accordingly. The calculation of the standard
deviation shall be brought up to date after every change of mix design.

Assumed Standard deviation (as per IS: 456- 2000) &IS: 10262- 2019

S. No. Grade of concrete Value of X Assumed standard

deviation N/mm2
(1) (2) (3) (4)
i) M 15 3.5
5.0
ii) M 20
5.5 4.0
M 25
iii) M 30
M 35
M 40
M 45 6.5 5.0
M 50
M 55
M 60
iv) M65
M70 8.0
6.0
M75
M80

1.2.1.3. Water cement ratio (W/C):

Water cement ratio is one of the key elements for a durable and sound concrete of
adequate strength. Accordingly, water cement ratio shall be maintained at correct value.
The water contents in both fine and coarse aggregate shall be determined regularly. The
amount of water to be added shall be adjusted to compensate for any observed variation in
moisture content. The amount of surface water may be estimated from the following table
in the absence of exact data:

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 Approx. quantity of surface water
S. No. Aggregate
% by mass litre/m3
1 Very wet sand 7.5 120
2 Moderately wet sand 5.0 80
3 Moist sand 2.5 40
4 Moist sand /crushed rock 1.25 to 2.5 20 to 40

1.2.1.4. Durability of Concrete:

It is essential that the concrete be durable viz., it should perform satisfactory in the
working environment during its anticipated exposure conditions during service. The materials
and mix proportions are to be such as to maintain its integrity, and (where ever applicable), to
protect embedded metal/reinforcement from corrosion. The different environmental exposure
conditions are given below:
Environmental Exposure Conditions (as per Table 3 of IS: 456- 2000)

S.No. Environment Exposure condition

1 Mild  Concrete surfaces protected against weather or aggressive

conditions, except those situated in coastal area.
 Concrete surfaces sheltered from severe rain or freezing
whilst wet.
 Concrete exposed to condensation and rain.
2 Moderate  Concrete continuously under water.
 Concrete in contact or buried under non-aggressive
soil/ground water.
 Concrete surfaces sheltered from saturated salt air in
coastal area.
 Concrete surfaces exposed to severe rain, alternate wetting
and drying, or occasional freezing whilst wet or severe
3 Severe condensation.
 Concrete completely immersed in sea water.
 Concrete exposed to coastal environment.
 Concrete surfaces exposed to sea water spray, corrosive
fumes or severe freezing conditions whilst wet.
4 Very Severe  Concrete in contact with or buried under aggressive
subsoil/ground water, concrete exposed to alternate wetting
& drying.
 Surface of members in tidal zone.
5 Extreme  Members in direct contact with liquid/solid aggressive
chemicals.
The severity level in the water resources works may be assumed moderate to severe
only, except in such environment which is associated with corrosive fumes or where the
concrete work is to be in contact with or buried under aggressive sub-soil /ground water.

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 The durability of concrete is influenced by many factors like
i) the environment, ii) the cover to the embedded steel, iii) the type & quality of constituent
materials, iv) the cement content & water/ cement ratio of concrete, v) workmanship, to obtain
full compaction and efficient curing, and vi) the shape & size of the member.

Among the above factors, the free water-cement ratio is an important factor in
governing the durability of concrete and should always be the lowest value. Appropriate
values for minimum cement content and the maximum free water-cement ratio are given in
Table 5 of IS: 456- 2000 for different exposure conditions. The minimum cement content and
maximum water-cement ratio apply to 20 mm nominal maximum size aggregate.

S. Exposure Plain Concrete Reinforced Concrete

No.

Minimum Maximum Minimum Minimum Maximum Minimum

Cement Free Grade of Cement Free Grade of
Content Water- Concrete Content Water- Concrete
kg/m3 Cement kg/m3 Cement
Ratio Ratio

(1) (2) (3) (4) (5) (6) (7) (8)

i) Mild 220 0.60 - 300 0.55 M 20

ii) Moderate 240 0.60 M 15 300 0.50 M 25

iii) Severe 250 0.50 M 20 320 0.45 M 30

Very
iv) 260 0.45 M 20 340 0.45 M 35
Severe

v) Extreme 280 0.40 M 25 360 0.40 M 40

1.2.1.5 Workability of concrete:

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 The concrete mix proportions chosen shall be such that the concrete is of adequate
workability for the placing conditions of the concrete and can be properly compacted.
Slump for good workability of concrete shall be as per mix design /as per IS: 456- 2000.

Placing Conditions Degree of Slump

Workability (mm)
(1) (2) (3)
Blinding Concrete; Very low Measurement of workability is
Shallow Sections; determined by compaction factor test
Pavements using pavers and 0.75 to 0.80 is suggested
Mass Concrete;
Lightly reinforced Low 25- 75
sections in slabs,
beams, walls, columns;
Floors;
Hand placed pavements;
Canal lining;
Strip footings
Heavily reinforced Medium 50- 100
sections in slabs,
Beams, Walls, Columns;
Slipform Work; Medium 75- 100
Pumped Concrete
Trench fill; High 100- 150
In-situ piling
Tremie Concrete Very high Measurement of workability by
determination of flow will be appropriate
through IS 9103

The Water-Cement ratio plays an important role in concrete mix. The water-cement
ratio shall be adopted as per the concrete mix design. The excess addition of water in the
concrete results in bleeding which decreases the strength of concrete and segregation of
cement, sand and metal. If less water is added to the concrete, it results in poor workability
and poor compaction.

1.2.1.6 Mixing:

Concrete ingredients shall be mixed thoroughly in the mechanical mixer and the
mixing shall be continued until there is a uniform distribution of the ingredients and the
mass is uniform in colour and consistency. Minimum mixing time shall be 2 minutes or as
determined by the Engineer-in-charge. The accuracy of the measuring equipment shall be

18
 within ±2 percent of the quantity of cement being measured and within ±3 percent of the
quantity of aggregate and water being measured.

Ready-mixed concrete (IS : 4926: 2003) shall be supplied having the quality and in
the quantity in accordance with the requirements agreed with the purchaser or his agent.
Notwithstanding this, the concrete supplied shall generally comply with the requirements
of 1S: 456.

1.2.1.7 Transporting:
Concrete shall be transported from the mixer to the form work / site of placement
as quickly as possible by methods, which shall prevent the segregation and maintain the
requisite workability. Transportation of concrete in ordinary open tippers or trucks shall
not be allowed as it causes segregation. Transit concrete mixers can be used for
transportation. Self loading, batching, mixing & transporting mixers can also be used both
for mixing and transporting concrete.
1.2.1.8 Placing:
The concrete shall be placed and compacted with vibrators (Immersion/ needle) and
plate vibrators in case of lining before initial setting of concrete commences and shall not
be subsequently disturbed. Methods of placing shall be such as to avoid segregation. Strict
and meticulous care shall be taken to avoid displacement of reinforcement or movement of
form work and concrete. Concrete shall be fully worked around reinforcement and in the
corners of form work. Over vibration resulting into bleeding of concrete shall be strictly
avoided. Spare vibrator shall be kept by the contractors as stand by. Temperature of
concrete, as placed, shall preferably be restricted to about 32ºC (90ºF). Proper care should
be taken to confine the concrete by placing the intermittent shuttering arrangements
wherever necessary.
1.2.1.9. Curing:

Curing shall commence as soon as possible after concrete is placed and initial set
has occurred but before it has hardened. Curing with water shall be continued for 28 days.
Exposed surfaces of concrete shall be kept continuously in a damp / wet condition by
pounding or by covering with a layer of sacking, canvas, hessian, or similar materials and
kept continuously wet for 28 days.

1.2.1.10. Sampling and strength of designed mix concrete:

19
 Sampling of concrete:
A random sampling procedure shall be adopted to ensure that each concrete batch
shall have a reasonable chance of being tested, viz. the sampling should be spread over the
entire period of concreting and cover all mixing units (concrete production units).

Frequency of sampling:
The minimum frequency of sampling of concrete of each grade shall be in
accordance with the IS 456-2000 or agreement conditions.

Quantity of concrete in
Number of samples Remarks
the work, m3

1-05 m3 1
06-15 m3 2
16-30 m3 3
31-50 m3 4
4 plus one additional sample for
51 m3 and above
each additional 50 m3 or part there
f
At least one sample shall be taken from each shift.

Test specimen :@nvv

Three specimens shall be made for each sample for testing at 28 days. Additional
specimens may be taken to determine the strength of concrete at 7 days. Test results of the
sample shall be the average of the strength of 3 specimens. The individual variation should
not be more than ±15% of the average strength of 3 specimens. If more, the test results of the
sample are considered invalid

1.2.1.11 Acceptance criteria of compressive strength:

The concrete shall be deemed to comply with the strength requirement when both the
following conditions are met, as per IS: 456-2013 amendment No.4

(a) The mean strength determined from any group of 4 non-overlapping consecutive test
results complied with the appropriate limits in columns 2 of the following table.
(b) Any individual test results complied with the appropriate limits in column 3 of the
following table.
Table: Characteristics compressive strength compliance requirements

20
 Mean of the group of 4 non-
Specified overlapping Individual test results in
grade consecutive test results in N/mm2
N/mm2
1 2 3
≥ fck + 0.825 x established standard
deviation (rounded off to nearest
M15 and ≥ fck – 3 N/mm2 or above
0.5N/mm2)
above
Or
fck + 3 N/mm2 whichever is greater.

In the absence of established value of standard deviation, the following value may be
assumed in the first instance and there after established values based on the requisite number
of test results.
For concrete of quantity up to 30 m3 (where the number of samples to be taken is
less than four as per the frequency of sampling, the mean of test results of all such samples
shall be fck + 4 N/mm2, minimum and the requirement of minimum individual test-results
shall be fck – 2 N/mm2, minimum however when the number of sample is only one as per
above table the requirement shall be fck + 4 N/mm2, minimum.
Concrete in the member represented by a core test shall be considered acceptable if
the average equivalent cube strength of the cores is equal to at-least 85% of the cube strength
of the grade of concrete specified for the corresponding age and no individual core has strength
less than 75 percent.

1.2.2 SELF COMPACTING CONCRETE:

[ IS 1199 (Part 1), IS 1199 (Part 2), IS 1199 (Part 6) and IS 10262 2019]

Self- compacting concrete (SCC) is an innovative concrete, which is highly flowable,

non-segregating concrete that fills uniformly and completely every corner of formwork by its
own weight and encapsulate reinforcement without any vibration, whilst maintaining
homogeneity.

1.2.2.1 Application Area:

Self- compacting concrete (SCC) may be used in precast concrete applications or for
concrete placed on site. SCC is used to cast sections with highly congested reinforcement and
in areas that present restricted access to placement and consolidation, including the
construction of tunnel lining sections and the casting of hybrid concrete- filled steel tubular
columns. It may be manufactured in a site batching plant or in a ready- mixed concrete plant

21
and delivered to site by truck mixer. It may be placed either by pumping or pouring into
horizontal or vertical forms.

1.2.2.2 Features of Fresh Self Compacting Concrete:

A concrete mix can only be classified as self- compacting concrete, if the requirements
for all below mentioned characteristics are fulfilled:

a) Filling ability (Flowability),

b) Passing ability,
c) Segregation resistance, and
d) Viscosity.

1.2.2.2 (a) Filling Ability (flow ability):

This is the ability of fresh concrete to flow into and fill all spaces within the formwork,
under its own weight. Slump- flow test is performed to test the flowability. Slump- flow value
describes the flowability of a fresh mix in unconfined condition. Visual observation during
the test can provide additional information on the segregation resistance and uniformity.
The following are typical slump-flow classes for a range of applications:
a) SF1 (slump flow 550 mm - 650 mm). This class of SCC is appropriate for:
1. Unreinforced or lightly reinforced concrete structures that are cast from the top with
free displacement from the delivery point (for example, housing slabs).
2. Casting by a pump injection system (for example, tunnel linings).
3. Sections that are small enough to prevent long horizontal flow (for example, piles and
some deep foundations).
b) SF2 (slump flow 660 mm - 750 mm) is suitable for normal applications (for example, walls,
columns).
c) SF3 (slump flow 760 mm - 850 mm) is used for vertical applications in heavily reinforced
structures, structures with complex shapes, or for filling under formwork. SF3 will often give
better surface finish than SF2 for normal vertical applications but segregation resistance is
more difficult to control.

22
1.2.2.2. (b) Viscosity:

Viscosity can be assessed by the V- funnel flow time as per IS 1199 (Part 6). Concrete
with a low viscosity will have a very quick initial flow and then stop. Concrete with a high
viscosity may continue to creep forward over an extended time.

A V- shaped funnel is filled with fresh concrete and the time taken for the concrete to
flow out of the funnel is measured and recorded as the V- funnel flow time. The viscosity is
divided into two classes, that is, V1 and V2. V1 has good filling ability even with congested
reinforcement. It is capable of self- leveling and generally has the best surface finish. V2 class
viscosity is more likely to exhibit thixotropic effects, which may be helpful in limiting the
formwork pressure or improving segregation resistance. But it may cause negative effects on
surface finish and sensitivity to stoppages or delays between successive lifts.
For V1 class, the time taken to pass the concrete from V- funnel shall be  8 s and for
V2 class the time taken to pass the concrete from V-funnel shall be between 8 s and 25 s.

1.2.2.2. (c) Passing Ability (Free from Blocking at Reinforcement):

Passing ability describes the capacity of the fresh mix to flow through confined spaces
and narrow openings such as areas of congested reinforcement without segregation. If there
is little or no reinforcement, there may be no need to specify passing ability as a requirement.
L- box test is performed to check the passing ability. The minimum ratio of the depth of the
concrete in the horizontal section relative to the depth of concrete vertical section is considered
to be 0.8. If the SCC flows as freely as water, it will be completely horizontal, and the ratio
will be equal to 1.0.

1.2.2.2. (d) Segregation Resistance (Stability):

This is the ability of fresh concrete to remain homogeneous in composition while in
its fresh state. Segregation resistance (sieve) test is performed to check this property of fresh
concrete.
After sampling, the fresh concrete is allowed to stand for 15 min and any separation
of bleed water is noted. The top part of the sample is then poured into a sieve with 4.75 mm
square apertures. After 2 min, the weight of material which has passed through the sieve is
recorded. The segregation ratio (SR) is then calculated as the proportion of the sample passing
through the sieve.
There are two classes of segregation resistance, namely SR1 and SR2. SR1 is generally
applicable for thin slabs and for vertical applications with a flow distance of less than 5 m and

23
a confinement gap greater than 80 mm. SR2 is preferred in vertical applications if the flow
distance is more than 5 m with a confinement gap greater than 80 mm in order to take care of
segregation during flow. For SR1 class segregation resistance shall be 15 to 20 percent and
for SR2 it shall be less than 15 percent. but if the flow is more than 5 m, a target SR value of
less than 10 percent is recommended. Segregation resistance becomes an important parameter
with higher slump-flow classes and/or the lower viscosity classes, or if placing conditions
promotes segregation. If none of these apply, it is usually not necessary to specify a
segregation resistance class.

The above properties of Self compacting concrete can be measured by different

equipments and they are as follows.

1.2.2.3 SLUMP- FLOW TEST AND t500 TEST:

This test specifies the procedure for determining the slump- flow and t500 time for self-
compacting concrete. The test is not suitable when the maximum size of the aggregate exceeds
40 mm.

1.2.2.3 (a) PRINCIPLE:

The slump- flow test is an indication of the flowability of self- compacting concrete in
the absence of obstructions. It is based on the slump test described in IS 1199 (Part 2). The
flow ability is evaluated by measuring the maximum spreading diameter (dmax) and the time
it reaches the spreading diameter of 500 mm (t500). The dmax of spreading is a measure of the
self- compacting concrete flow range when subjected to load from its own weight. It is an
indication of the yield stress of the self- compacting concrete. The t500 time is a measure of
the speed of flow and an indication of the relative viscosity of the self- compacting concrete.
The result is an indication of the filling ability of self- compacting concrete. The fresh concrete
is poured into a cone as used for the IS 1199 (Part 2) slump test. When the cone is withdrawn
upwards the time from commencing upward movement of the cone to when the concrete has
flowed to a diameter of 500 mm is measured; this is the t500 time. The largest diameter of the
flow spread of the concrete and the diameter of the spread at right angles to it are then
measured and the mean diameter is the slump- flow.

1.2.2.4 V- FUNNEL TEST:

This test specifies the procedure for determining the V- funnel flow time for self-
compacting concrete. The test is not suitable when the maximum size of the aggregate exceeds

24
20 mm. The V- funnel test is used to assess the viscosity and filling ability of self- compacting
concrete.
1.2.2.4 (a)PRINCIPLE:
A V shaped funnel is filled with fresh concrete and the time taken for the concrete to
flow out of the funnel is measured and recorded as the V- funnel flow time.
1.2.2.5 L- BOX TEST:
The L- box test is used to assess the passing ability of self- compacting concrete to
flow through tight openings including spaces between reinforcing bars and other obstructions
without segregation or blocking.
1.2.2.5 (a) PRINCIPLE:
The L- box test is used to assess the passing ability of self- compacting concrete. There
are two variations; the two bar test and the three bar test. Only the three bar test is covered in
this section, as it simulates more congested reinforcement.
A measured volume of fresh concrete is allowed to flow horizontally through the gaps
between vertical, smooth reinforcing bars. The heights of the concrete in the vertical section
(H1) and at the end of the horizontal section (H2) are measured and the ratio H2/H1 determined.
This ratio is a measure of the passing or blocking behaviour of self- compacting concrete.
1.2.2.6. SIEVE SEGREGATION RESISTANCE TEST:
This test specifies the procedure for determining the sieve segregation resistance of
self-compacting concrete.
1.2.2.6 (a) PRINCIPLE:
The sieve segregation resistance test is used to assess the resistance of self-compacting
concrete to segregation. After sampling, the fresh concrete is allowed to stand for 15 min and
any separation of bleed water is noted. A known weight of the sample is then poured into a
sieve with 4.75 mm2 apertures. After 2 min the weight of material which has passed through
the sieve is recorded. The segregation ratio is then calculated as the proportion of the sample
passing through the sieve.

1.2.3 CONSTRUCTION JOINTS & TECHNIQUE OF GREEN CUTTING

1.2.3.1. CONSTRUCTION JOINTS:

Concrete shall be placed in massive structures in lifts which are generally maximum
of 1.5 m high. To develop proper bond between the lifts, the concrete surface shall be freed
of all laitance, coating stains, defective concrete and all foreign material and the surface

25
 shall be roughened. This can be achieved by green-cutting. For lining work the construction
joint where ever required is to be adopted as per the sketch in Annexure –II

1.2.3.2. GREEN CUTTING:

The surface of the joint shall be thoroughly green-cut with an air-water jet. Green
cutting is usually done 8 to 12 hours after the top surface of a concrete lift has been
completed and sufficiently hardened. The actual time for taking up the green cutting
operation shall depend upon the following factors:
a) Concrete placement temperature,
b) Atmospheric temperature,
c) Concrete mix, and
d) Slump.
The air-water jet will remove the thin surface film of laitance and grout to expose clean
surface.

Green cutting, if done at the proper time, shall yield very good results. When started
too early, it shall result in over-cutting and removing too much mortar. It is also liable to
loosen the aggregate particle and leaving too poor a surface to bind the fresh concrete. On the
other hand, if green-cutting is delayed too long, the cutting action of the air and water jet
would be ineffective for proper removal of laitance., therefore requires much greater care and
judgement for proper use at the proper time

1.2.3.3. SKILL OF JET OPERATOR:

Besides determining the power time for initiating green-cutting, the process will
require constant attention on the part of the air-water jet operator. By correct manipulation of
the high velocity air-water jet, a trained operator can ensure the removal of the thin surface
film of laitance and grout effectively and at the same time leaving the aggregate stones,
already embedded in the mortar, undisturbed.

1.2.3.4 PROPER AIR-WATER GUN:

In addition to the skill of the operator, a proper air-water gun in also a vital requirement
for effective green-cutting. The issuing nozzle must be about 460 mm (18 inches) long to
ensure the requisite cutting force close to the concrete surface. A dimensioned sketch of air-
water gun.

26
1.2.3.5 SAND BLASTING:
Sand blasting is the process of roughening and cleaning the surface of old and set
concrete by means of coarse sand and air applied under pressure of 6.33 to 7.03 kilograms per
square centimetre (90 to 100 pounds per square inch) through a nozzle, so as to erode the
laitance and grout from the old and fresh concretes monolithic. Sand blasting of rock is also
done so that concrete may be placed on or against a clean surface as required according to
specifications.
There are two types of sand blasting namely “wet sand blasting” and “dry sand
blasting”. In wet sand blasting water is also used along with sand and air under pressure, while
in the latter, only sand and air under pressure are used. Normally the concrete and rock surface
etc., are wet sand blasted to keep down the dust.

1.2.3.6. ADMIXTURES(IS 456: 2000, IS 9103: 1999 & IS 10262: 2019)

In addition to the normal constituents (cement, fine aggregate, coarse aggregate and water),
other additives are added to concrete to achieve desired properties of concrete in plastic or
hardened state are called admixtures.
There are different types of admixtures which are as follows:
1) Chemical Admixtures and 2) Mineral Admixtures.
1) Chemical Admixtures: The different types of chemical admixtures are

1. Accelerating Admixture,
2. Retarding Admixture,
3. Water reducing Admixture,
4. Air entraining Admixture, and
5. Super plasticizing Admixture.

2) Mineral Admixtures: The mineral admixtures are the partial replacement of cement. The
different types of mineral admixtures are

1. Fly ash,
2. Ground granulated blast furnace slag (GGBS),
3. Metakaolin, and
4. Silica Fume.
The recommended dosages of different mineral admixtures materials for high strength mixes
are given in the Table below

27
 S. No. Mineral Admixture Recommended Dosages, Percentage by
Mass of Total Cementitious Materials
(1) (2) (3)
i. Fly ash 15- 30
ii. Ground granulated blast furnace slag 25- 50
iii. Metakaolin 5- 15
iv. Silica Fume 5- 10
In areas of heavy, congested reinforcement and poor accessibility, pumping of concrete
becomes inevitable and takes longer time without the process of pumping. The concrete mix
is to be designed with high workability, generally the slump of 60 mm. specified in the
agreement is not at all sufficient. Further at high cement, air entrained concrete becomes sticky
and difficult to flush. But as per ACI report concrete with a slump greater than 190 mm. that
remains cohesive without excessive bleeding and segregation or abnormal retardation is
known as flowing concrete. Flowing concrete is useful for pumping because it reduces
pumping pressure and increases both the rate and distance that the concrete can be pumped.

For pipe, about 150 Cum, of concrete per day is to laid at difficult placement conditions. To
produce flowing, self compacting concrete without losing the required strength and with
reduction in usage of free water content, Super-plasticisers available in market are used with
a slump of 150 mm.

With the usage of Super-plasticisers in the pipe concrete, the workability of concrete is
considerably increased and the period of time that the concrete is to be placed and compacted
is well sufficient. The surface finish of the concrete is very smooth without honey-combing.
The concrete produced with the usage of super-plasticisers is dense and impermeable.
The admixture product may also be marked with standard mark of BIS. The performance
of admixture is evaluated by comparing properties of concrete with the admixture under test
with those of concrete without any admixture.

The chemical admixtures have to be tested for different properties such as

i) Physical state (either liquid or solid) and colour,

ii) Ash content,
iii) Relative Density,
iv) Chloride Ion Content and
v) pH value

28
 The most common admixture affects plasticity, air entrainment and curing time. The
concrete admixtures should be used judiciously according to agreement specification and
method of application to avoid adverse effect on concrete properties at fresh and hardened
straight.

DO’S & DO NOT’S

A) FOR FOUNDATION:
DOS DO NOT’S
1. Verify dimensions and foundation levels 1. Do not forget to compare
as per drawing. capacity of actual soils met with
2. Wet the foundation surface to a depth of design strength.
150 mm or to impermeable material. 2. Don’t lay the foundation
3. Ensure the rock surface free from oil, concrete without wetting the
objectionable coating unsound surface.
fragments. 3. Do not lay the concrete under
4. Check-up correct batching of water and over slush.
ingredients. 4. The minimum mixing time
5. Check the batch of cement and its make. should not be less than 2 min.
6. Check-up water cement ratio and slump 5. Do not forget to keep stand by
test. vibrator and needles.
7. Ensure uniform mixing. 6. Do not place concrete in raw or
8. Ensure proper compaction with vibrators insufficiently heavy mortar, as
and keep stand-by vibrator and needles. mortar may wash from
9. Operate Immersion type vibrators nearly concrete.
in vertical position to vertical drain. 7. Do not forget to cast the cubes.
10. Cure with water for 28 days. 8. Do not allow segregation of
11. Compact with suitable bedding concrete
materials in case of over excavations 9. Do not use unsatisfactory mix.
and with suitablegrade concrete in case 10. Don’t allow admixtures which
of rock. will harm the strength of
12. Confine Concrete with intermittent concrete.
shuttering
13. Allow admixtures as per I.S. 9103-1999.

29
B) SUPER STRUCTURE:
DOS DO NOT’S
1. Check the form work. 1. Avoid abrupt surface irregularities.
2. Apply cement slurry after cleaning 2. Do not deviate from specified
the surface at vertical joints. dimensions of cross section from -6
3. Clean and cover with a layer of 10 to mm to +12 mm.
15 mm thick mortar of the same 3. Do not allow concreting until all
proportion of concrete mix for form work installation of items to be
horizontal joints. embedded and preparation of surface
4. Place the concrete at temperature involved are approved.
between 15° C to 32° C.
5. The concrete shall be discharged
within30 mins after introducing of the
mix water and cement.

B) REINFORCED CEMENT CONCRETE SLABS: (IS CODES 2502, 1786)

DOS DO NOT’S
i. Check for testing of Sectional Weight, Ultimate Strength, i. Do not pass
Ductility, Bend & Re-Bend at Central Laboratory when without proper
determined as described in Indian Standard are within cover.
limits and found satisfactory. ii. Do not allow less
ii. Check the reinforcement as per drawing. lengths in over laps.
iii. Do not allow
iii. Check for the placing of Main and distribution bars concrete until the
orientation as per the drawing. cavities of the
iv. Check the cover as per the drawing. shuttering are
completely closed.
v. Check for the alternative overlapping, length of the iv. Do not allow
overlapping and developing length as per the design. concrete until the
vi. Check for the proper tying of the reinforcement. surface is dry and
free from
vii. Check for the extra bars as per the drawing, if any. deleterious matter.
viii. Check for the anchor bars/hook bars/crank bars as per v. Do not allow
drawings. If any concrete until the
steel is free from
ix. Provide asphaltic pad and water stopper as per drawing.
Rusting/corrosion.

30
4. PREPARATION OF SUB-GRADE FOR C.C. LINING

31
 1.3.0. PREPARATION OF SUB-GRADE FOR C.C. LINING
(IS CODE: 2720, 4701,3873)

1.3.1 PREPARATION OF SUB-GRADE:

Preparation of sub-grade is a major factor for efficient lining. Failure or cracking of
lining in many cases can be attributed in some measure to poor preparation of sub-grade. Due
emphasis is therefore to be laid on control and proper preparation of sub-grade for lining. Sub-
grade indifferent soil reaches shall be prepared based on IS: 3873-1993.

Whereas the work of trimming the canal section up to profile of lining shall be carried
out well in advance, the trimming of proud section equivalent to the thickness of lining should
be carried out immediately prior to laying of lining but in no case the time interval shall exceed
3 days in normal weather and 2 days in adverse condition.

1.3.1.1 Preparation of Sub –Grade consisting of Earth:

1. The sub-grade should be prepared, dressed and rolled true to level according to the required
cross-section of the canal to form a firm compacted bed for the lining. Sample profiles true to
the cross section of the canals should be made at suitable intervals to ensure correct formation
of the sub-grade. If at any point material of sub-grade has been excavated beyond the neat
lines required to receive lining. The excess excavation should be filled with material
compatible with sub-grade material and thoroughly compacted.

2. When partial filling of existing canal section is necessary to reduce the cross sectional area
to that required for lined canal, the fill shall be place and suitable compaction by
rolling/compaction/mechanical tampers to form firm foundation for placing the lining to avoid
its settlement. Slope compaction shall also be used is required for effective compaction of sub
grade to the specified density.

3. The compaction of the bed in predominantly sandy reaches should be done by over
saturating the bed by flooding it with water before lining is laid. The compaction of sides in
such reaches should be done by over cutting the sub-grade by 15 cm. And re-filling it with
lean mortar with adequate quantities of cement or by vibro-compactors. The relative density
of the compacted sub-grade shall be at-least 70 %.

4. All compaction in other than predominantly sandy reaches should be done at optimum
moisture content in layers not more than 15 cm thick to obtain a dry bulk density of not less
than 95 percent of the density at optimum moisture content. Compaction of sub-grade

32
depending upon the position of sub-soil water level shall be carried out in accordance with I.S
3873 – 1993 (In-situ cement concrete lining in canals).

5. Where placing and compacting bedding material is on sloping foundation, the layers shall
be placed parallel to the surface of the foundation. If at any point the foundation material is
disturbed or loosened, it shall be moistened if necessary and thoroughly compacted to form
foundation for placing the lining.

6. All along the canal alignment, the rain cuts on the inner slopes of the Banks shall be filled
up with approved soil and shall be compacted thoroughly to required lines, dimensions and
levels.

7. If at any place, placement of bedding material below the proposed lining is required, due
care shall be taken to place the bedding material on scientifically approved surface adequately
moistened in layer not exceeding 15 cm in a single operation and thoroughly compacted.

8. All loose materials likely to be present at the end panel of existing lining adjacent to which
lining is to be placed shall be removed and all voids beneath the existing lining shall be refilled
and compacted thoroughly.

1.3.1.2. Sub-grade density and Moisture Control:

A sound dense earth foundation, carefully trimmed and pre-moistened are critical steps
before lining placement, prerequisite to a good lining construction. Required foundation
density of embankment and preparation coupled with moisture control are the key
requirement. At the time concrete is placed the sub grade is required to be thoroughly moist
(but not muddy) for a depth of about 15 cm and 20 cm in case of sand or the concrete would
extract moisture from the sub-grade. Photographic record showing the actual use of very fine
spray nozzles instead of hose (for moistening the compacted sub-grade) should also be kept.
Compliance of these requirements must be recorded by Execution and Quality Control staff
in the O.K Cards.

1.3.1.3. Preparation of Sub Grade consisting of Rock:

The Sub-grade should be prepared and dressed true to level and according to the
required cross-section of the canal. All excavation including over-breaking below lines of
underside of lining should be filled completely up to the lines of the underside of lining with
suitable material. Viz., spalls lean concrete or gravel and aggregate. The bed may be
compacted with rollers and sides with rammers to form a firm backing for the lining. Care

33
should be exercised in selecting refill material for use over fractured rock of rubbles because
of the danger of washing of fines into the sub-grade voids and thus loosing support.

1.3.1.4. Preparation of sub grade consisting of Expansive soils (IS. 9451:1994):

Field and laboratory experiments shall be carried out to determine the physical,
textural, Engineering and Chemical properties of the black cotton soils/expansive soils and
evaluate the swelling pressures of soils in various reaches to establish the thickness of CNS
layer required so that the resulting deformation is within the permissible limit.

Criteria for fixing the thickness of CNS layer:

1. Thickness of CNS material is related to swelling pressure and the resultant

deformation. The permissible deformation is 2 cm.

2. Guidelines for choosing the CNS material should be as per IS 9451: 1994.

In respect of the provision of CNS layer in the bed, it shall be as worked out from the
consideration of swelling pressure. However, the thickness of CNS layer to be provided on
slopes shall, in addition, be governed by the construction consideration viz., from rollable
width consideration for achieving effective compaction.

Making due allowance for field controls, variations in the properties of CNS material
in the field, an optimum thickness of 1 m of CNS material shall be adopted on side slopes
(perpendicular to slope) of main/branch canals of 1.5:1 slope. Also, the CNS material shall be
laid and compacted to 0.45 in beyond the finished profile (wherever directed by the Engineer).
This will provide a horizontal width of about 2.25 in corresponding to the Canal slope of 1.5:
1 which is the optimum width required for compaction by power driven 8 T to 10T rollers.
The extra width so laid shall be trimmed to the required profile. Sketch is enclosed in
Annexure – III.

Table 1: Thickness of CNS layer in channels of carrying capacity less than 2 Cumecs

Discharge in Cumecs Thickness of CNS layer in cm (Min.)

(m3/sec)
Swell Pressure Swell Pressure
50 - 150 kN/m2 More than 150 kN/m2
1.4 – 2.0 (50 to 70 cusecs) 60 cm 75 cm

0.7 – 1.4 (25 to 50 cusecs) 50 cm 60 cm

0.3 – 0.7 (10 to 25 cusecs) 40 cm 50 cm

34
 0.03 – 0.3 (1 to 10 cusecs) 30 cm 40 cm

Table 2: Thickness of CNS layer in channels of carrying capacity of 2 Cumecs and More

Swell Pressure of soil Thickness of CNS layer in cm (Min.)

KN/m2
50 to 150 75 cm

150 to 300 85 cm

300 to 500 100 cm

NOTE - However, optimum thickness of CNS materials needs to be determined for different
swelling pressures by actual experiments both in field and laboratory; if required.

Specification of CNS Soil

(i) Gradation of C.N.S. Soil
1. Clay (less than 2 microns) – 15 to 20 %
2. Silt – (0.06 mm – 0.002 mm) – 30 to 40%
3. Sand (2mm – 0.06mm) – 30 to 40 %
4. Gravel (Greater than 2 mm) – 0 to 10 %
(ii) The CNS material shall be non-swelling, with a maximum swelling pressure of 10
KN/m2 when tested in accordance with IS 2720 (Part- 41)– 1977 at optimum moisture content
over dry condition and minimum cohesion

(iii) Index Properties:

Liquid Limit Less than 50% but greater than 30 %
Plastically Index Less than 30% but greater than 15%.
If given CNS material is not available, designed soils mix to produce artificial CNS
may be used. The artificial CNS shall broadly satisfy all the requirements of CNS outlined
above.
In respect of the provisions of CNS layer in the bed, it shall be as worked out from
consideration of swelling pressure. However, the thickness of CNS layer to be provided on
slopes shall, in addition, be governed by the construction consideration viz. from the Power
Roller rollable width consideration for achieving effective compaction. CNS layers shall be
compacted to 98% proctor density.

Note: During construction, it shall be ensured that:

35
 i. Serrations/steps/benches shall be provided in the side slopes of canal in cutting to
provide a good bond between the CNS layers and expansive soil and to also prevent
contact slides between CNS materials and expansive soil.
ii. Proper moisture shall be added to CNS material and expansive soil.
iii. CNS material shall be laid in layers (20 cm thickness) and compacted to requisite
proctor density, preferably, by Power Roller.
iv. To avoid slipping and rain cuts during the rainy season, it shall be advisable to provide
CNS right up to the ground level.
v. The sub grade on which CNS layer is to be laid shall, generally, be not kept exposed
for more than 4 days prior to the placement of CNS layer.
vi. Effective compaction of sub grade for side lining on slopes is very important in cutting
or embankments. In addition to the designed thickness of CNS, 20 cm or more
(perpendicular to side slope) of extra thickness (called proud) shall be provided and
compacted. This proud shall be removed only just prior to the placement of lining (a
time interval of, say, about one day), thus making a fresh and well-compacted surface
available for bedding. In small section channels, it shall be appropriate to over
excavate the section, and fill the entire section with CNS material (laid in successive
layers and compacted to 98% proctor density), and, thereafter, scoop this section to
the designed section for placement of lining. This PAD method ensures effective
compaction by 8-10 T power rollers or equivalent power vibratory rollers. The CNS
material so scooped out is utilized in the next reach through re-handling.
vii. To avoid slipping and rain cuts during the rainy seasons, the CNS shall be provided
right up to ground level in cutting reaches.
viii. Under drainage arrangement, as per provisions in the agreement.

1.3.2 SUB-GRADE DENSITY AND MOISTURE CONTROL:

A sound dense earth foundation, carefully trimmed and pre-moistened before lining
placement are critical steps, prerequisite to a good lining construction. Required foundation
density of embankment and preparation coupled with moisture control are the key
requirement. At the time, concrete is placed the sub-grade is required to be thoroughly moist
(but not muddy) for a depth of about 12 to 15 cm and 20 to 22 cm in case of sand as else the
concrete would extract moisture from the sub-grade. Compliance of these requirements must
be recorded by the execution, QC staff in the OK card. Photographic record showing the actual

36
use of very fine spray nozzles instead of hose (for moistening the compacted sub-grade)
should also be kept.
DO’S & DO NOT’S

Lining Preparation of Sub-grade

DOS DO NOT’S
1. Check the model section to the canal profile 1. Do not allow concrete lining on loose
i.e., bottom or lining. sub-grade.
2. Check the canal profile with reference to 2. Do not allow any root of stumps to be on
model sections. sub-grade.
3. Remove roots and stumps completely from 3. Do not allow lining in expansive soils
the sub-grade. without treatment with C.N.S. soils.
4. Compact over excavation in soils with 4. Do not place the porous plug below the
gravel duly wetted. surface of the lining.
5. Compact over excavation in rocky area with 5. Do not allow lining without wetting the
gravel spalls and aggregate spalls and sub grade suitably.
aggregate duly wetted.
6. Provide treatment with C.N.S soils in
expansive soils i.e., 0.6 mtrs., thick for
discharge up to 50 cusecs.
7. Provide porous plug of size 375 mm long x
100 mm dia in each panel with local filters
of graded metal and sand size 600 x 600 x
750 mm.
8. Provide longitudinal and transverse drain of
size 600 x 750 mm filled up with graded
metal and sand as per drawing.
9. Check whether porous plugs are freely
draining or not.
10. Note down December water table for
providing longitudinal drains and other
relief measures (as per drawing)

37
4 C.C. LINING

38
 1.4. C.C. LINING (I.S. CODES 269, 383, 456, 516, 2116,4558,
5256, 9451,10430)

1.4.0 PROCEDURE FOR EXECUTING CONCRETE LINING

(I) GENERAL:
i) The area shall be cleared of the objectionable material, before taking up lining work.
ii) Center line, bed-width, inner & outer slopes etc. With the due provision for proud
cutting shall be marked before start of trimming or bed excavation.
iii) The excavation for trimming for preparing base for lining, i.e. sub grade shall be carried
out / - (trimmed prior to lining) and to the profile. Trimming should not be exposed
much before the actual starting of the lining of the work so as to preserve the O.M.C.
in soil which comes in contact with cement mortar layer of the lining. Over cutting shall
be avoided. However, over excavated portion shall be filled up with suitable material,
moisture and compacted to the required density by tamping, rolling or slope compactor
so as to form properly compacted sub-grade to receive the concrete for lining.
iv) Check the profile of sub-grade so prepared and also check and record the density and
the moisture content of sub grade. All loose materials on sub grade shall be removed
and compacted suitably if required, by slope compacters.
v) In case where rocky strata is met with over excavation shall have to be carried out as
specified and shall be filled up with the selected material and compacted as per
requirement.
vi) Necessary under drainage arrangements shall be provided.
(II) Mechanized Lining:
i) The thickness of in situ cement concrete lining to be provided in the main canals, branch
canals, majors, and minors is indicated in the drawings.
ii) Paver machine (Cylinder forming type) used for lining consists of conveyer belt, paver
and foot bridge.
iii) Temporary rails on wooden sleepers are laid for movement of conveyor belt and paver
assembly. It is therefore very important to maintain the line and levels of the rails to
achieve the required uniform thickness of concrete, proper placement, compaction,
finishing and maintaining profile. As such, wooden sleepers shall be provided at closer
interval of nearly 0.50 m for ensuring firm fixation of rails. Level shall be marked on
jacks of the paver to achieve the desired uniform thickness of concrete.

39
iv) Behind the roller, an attachment for inserting PVC strip Joint /chatter for cutting groves
are provided. Similar attachment for providing transverse joints at 4 m c/c is also
attached. In case of PVC strips, the position of transverse joints at maximum @ 4 m c/c
shall be marked and the fin of longitudinal joints shall be cut to accommodate the
transverse joint at the crossings.
v) A work bridge is also provided to follow the movement of paver for attending to the
finishing of concrete and working of labours during lining, operation and subsequently
for application of curing compound.

(III) Materials:
i) Cement either OPC or PPC to be used shall be got tested in advance. Cement older than
90 days shall not be used without retesting and prior approval of Engineer-in-charge.
ii) Fine Aggregate: Sand shall confirm to the requirement of IS: 383-2016 and other
relevant specifications. Sand shall be tested for gradation, specific gravity, water
absorption, fineness modulus, spectrographic analysis etc. It should be brought from
approved quarry / Source with requisite F.M. of 2.4 to 3.2 or as specified.
iii) Coarse Aggregate:
a. Coarse aggregate for concrete shall be clean, hard, dense, free from vegetation it-
shall be confirming to IS: 383- 2016 or the specification concerned with the work.
Predominately flaky and elongated aggregate shall not be used. Gravel / metal shall
be brought from the approved source/ quarry only and shall be tested for their
gradation, specific gravity, water absorption, impact and abrasion values, soundness,
spectrographic analysis, flakiness and elongation.
b. Each grade of material ranging from 40 mm to 4.75 mm shall be stacked separately.
iv) Water: Potable water free from any other deleterious material shall be used. Water shall
be got tested as per relevant standards.
v) Admixture: Air entraining agent (AEA) as an admixture shall be added to the concrete
batch as per the dose prescribed in the mix-design.

(IV) Manufacturing of cement concrete:

@nvv

40
i) The concrete shall be manufactured of the controlled grade as specified with suitable
admixture, using well graded aggregate with msa 40/20/10 mm, OPC or PPC cement,
coarse aggregate, sand etc. in accordance with the mix design.
ii) Concrete should be properly mixed in mixing plant or tilting type mixer. The weighting
and measuring equipment, i.e., batching plant or weight batcher shall operate within the
limits of accuracy specified. They shall be calibrated regularly to ensure accurate
performance.
iii) The Proportion of different types of aggregate, sand, cement and water, and w/c ratio
shall be in accordance with design mix and necessary correction for variation for over
size and undersize and water absorption shall be made. Time of mixing shall be in
accordance with specification to obtain dense, plastic, with uniform distribution of
material and the concrete of uniform colour and consistency.
iv) Mixer efficiency test shall be conducted from time to time.

(V) Transporting, Placing & compaction of Concrete:

i) Concrete manufactured shall be handled from the place of mixing to the place of deposit
as rapidly as practicable by use of transit mixers in agitating conditions or suitable
placers and placed in final position within the specified time. Alternatively, mobile "Self
Loading, weight-batching & mixing and transporting concrete mixture (of ± 2.5 m3drum
capacity)" viz. visibly moving B & M plant can be deployed.
ii) During placement segregation of concrete should be avoided.
iii) Before placing of concrete, sub-grade shall be moistened adequately.
iv) Concrete shall be placed directly to the final position and shall not be allowed to flow.
v) Manual placing of the concrete shall not be permitted. Suitable means to convey the
concrete shall be provided to avoid free fall of concrete from the unacceptable height or
angle.
vi) Cutting grooves or inserting PVC strip, for longitudinal and transverse joints shall be
attended as per the requirement.
vii) The surface of the concrete finished and vibrated shall be even, smooth and free from
pockets, projections, honey combing and other objectionable defects.

(VI) Curing of Concrete:

41
 i) The concrete lining shall be cured with water/liquid membrane forming liquid
membrane as per specification.
ii) Curing compound to be used shall be confirming to the relevant ASTM standards. It
should be got tested for water retention and reflectance. Curing compound as per
relevant ASTM-C-309 and ASTM-C-156 and other ASTM standard well in advance
before use.
iii) Curing compound shall be sprayed only by mechanical sprayer to ensure uniform and
continuous application on concrete surface. The coverage achieved shall be kept on
record and maintained regularly. The curing compound shall be sprayed / applied as
soon as water is disappeared &curing compound sprayed shall not mix with the concrete.
Record of test results of curing compound its coverage and consumption shall be
maintained.
iv) Record for curing period in case of water curing as per specification shall be maintained.
Vehicles shall not be allowed on lining work.

(VII) Testing of concrete:

i) Concrete shall be tested for workability, temperature, at Batching Plant & site. cubes
shall be cast at site.
ii) Concrete shall be tested at site and in Laboratory on representative sample collected at
site during laying in accordance with relevant specifications. Sampling procedure,
frequency and preparation of test specimens etc. shall be followed as per the relevant
specification.
iii) Test strength of samples shall be compared and evaluated as per the provisions contained
in the specifications.
iv) Concrete shall be accepted as per the acceptance criteria laid down in the relevant
specification.
v) Cores from the hardened concrete shall be taken to check the thickness, density, water
absorption and compressive strength etc.,
vi) Records to be maintained.

1.4.1 CONCRETE CORES FROM CANAL LINING AND OTHER STRUCTURES

A specimen to be tested for strength shall not be removed from the structure until the
concrete has become hard enough to permit its removal without disturbing the bond between
the mortar and the coarse aggregate. In general, the concrete shall be 28 days old before the

42
specimens are removed. Specimens that show abnormal defects or that have been damaged in
removal shall not be used. (IS:457-1957).

Government issued memo exempting core extraction from lining works lesser than 75
mm thick for assessing strength but otherwise the core may be extracted for determination of
density, water permeability and thickness etc.

TEST OF DRILL CORES:

A good canal lining should be strong, durable and of optimum water tightness. A well
graded concrete mix, composed of sound aggregates with a close control on its workability as
well as placement on a dense sub-grade, followed by good finishing and adequate curing shall
ensure a sound lining capable of a long service life.

As the lining work progress, testing of the output should be taken up on a regular basis
accordingly, to evaluate the quality of concrete lining completed and cured (for 28 days) in
respective reaches, cores should be taken of lining concrete. Frequency of drill cores could be
say one core each from bed, side lining per 2,000 square meter of in situ-lining. The frequency
shall be decided by the Engineer-in-Charge.

The cores should be inspected for:

1. Segregation
2. Honey combing and
3. Thickness of lining
The cores should be tested for
1. Density (g/cc)
2. Compressive strength and
3. Water absorption.
A standard test cylinder has a diameter one-half of its height viz., the Length (L)/
Diameter (D) ratio is 2. However, the cores taken from in-situ-lining shall not have these
relative dimensions and consequently L/D ratio will not be 2. Accordingly, the test strengths
of these cores should need to be corrected. The curve in Attachment be used to correct the
indicated strengths so that they will be comparable with those obtained from standard
specimens. The equivalent cube strength of the concrete shall be determined by multiplying
the corrected cylinder strength by 5/4. As per clause no. 8.4.2 of IS 516 Part 4: 2018, the
correction factor is determined by the following equation.

F= 0.11N +0.78,

43
 Where
F= Correction Factor, and
N= length/ diameter ratio.

The cores should be properly stacked in sheds.

Complete data and test results of cores should be meticulously recorded. It should include.
• Location of test core (chainage: bed and side slope lining panel).
• Grade of concrete mix, maximum size aggregate of insitu-lining, slump, W/C ratio.
• Density of standard specimen prepared and cured in laboratory.
• Density of test core (g/cc).
• Thickness of lining exhibited by the test core.
• Compressive strength of test core.
• Corrected compressive strength (asper curve of Attachment A) in kg/cm2
• Water absorption in percentage.
• Remarks-visual observations on any honey combing/segregation viz. lack of
consolidation be recorded.
Separate quality audit team shall review the results of tests performed on materials by
the Quality Control staff and for some tests got conducted through TGERL, Hyderabad/NCB
and CSMRS laboratories, New Delhi.
Acceptance Criteria: - IS 516 (Part IV): 2018

Concrete in the member represented by a core test shall be considered acceptable if

the average equivalent cube strength of the cores is equal to at-least 85% of the cube strength
of the grade of concrete specified for the corresponding age and no individual core has strength
less than 75 percent.

Moisture Conditioning:
Test specimens shall be completely submerged in water at room temperature for 40 to
48 hours immediately prior to the compression test. Specimens shall be tested promptly after
removal from water storage. The testing shall be done in accordance with the guide lines laid
down in IS 516-2018 Part 4, complete data and test results of cores should be meticulously
recorded as per format enclosed (Annexure – IV).

DOS DO NOT’S
1. Check the canal prism and verify the 1. Do not allow the concrete over
bed levels. loose sub-grade.

44
2. Check the gradation analysis of fine 2. Do not allow lining without wetting
and coarse aggregate to the sub-grade.
requirement of mix at batching plant. 3. Do not allow C.C lining manually
3. Allow the ingredients of fine and without vibration.
coarse aggregate as per required mix 4. Do not allow segregation of
by weigh batching. concrete while laying through
4. Check the calibration of weighing discharge conveyor.
machine at batching plant. 5. Do not allow concrete directly on
5. Check the water meter and its sub-grade from transit mixer.
discharge. 6. Do not form contraction joints over
6. Check the batch of cement, its make longitudinal drains.
and test results. 7. Do not fill up contraction joints
7. Check the water cement ratio and with sealing compound without
record the slump. cleaning with air water jet or sand
8. Check whether any retarders and air blast.
entertaining agents are added. 8. Do not allow any projections or
contraction joint over the surface of
9. Maintain load register. the lining.
9. Do not allow C.C lining without
10. Record the No. CC cubes cast and its applying suitable primer to sides,
compressive strength. 10. Do not remove the channels
11. Cure CC Lining with water for 28 immediately before setting of C.C.
days. 11. Do not use untested cement.
12. Ensure smooth surface with paver
roller passes. 12. Do not allow to sink the porous
13. Form the contraction and plugs in the drains.
construction joints as per approved 13. Do not allow lining without making
drawing. proper arrangements for curing
14. Check the thickness of C.C Lining with water.
for each panel. 14. The Co-efficient of variation in the
15. Checking placing of mastic pad at compressive strength of cement
structures of construction joints. should not be more than 8%.
16. Allow concrete lining at temperature
between 150C and 300C.
17. Check periodically the coefficient of
variation in the compressive strength
of cement.
18. The batching plant to be used shall
confirmed to the required of IS 4925-
1968.

45
5.SHOTCRETING AND GUNITING

46
1.5. SHOTCRETING AND GUNITING (IS 9012: 1978)
1.5.0. INTRODUCTION
Shotcreting has been referred initially as guniting.

Guniting: Gunite is trade name for dry gunned concrete. It is the pneumatic
application of mortar of less thickness projected at a high velocity on to a surface. It refers to
only dry mix process. This requires a very skilled person especially in the case of thick or
heavily reinforced section.

Shotcreting: It is a recent development on the similar principle of guniting for

achieving greater thickness with small coarse aggregate and waste created by sprayed concrete
falling to floor is usually half for shotcrete as compared to gunite.

1.5.1 PURPOSE OF GUNITING:

Guniting is a particularly useful method for repairing R.C.C. columns and beams which have
cracked or where reinforcement has deteriorated. Form work is not usually necessary, and even
intricate shapes can be successfully constructed; and it is slow process compare to shotcrete
method.

1.5.2 PURPOSE OF SHOTCRETING:

1. Shotcreting is suitable for a variety of new construction and repair work, but its properties
and performance are to a great extent dependent on the conditions under which it is placed, the
capability of the particular equipment selected, and in particular on the competence of the
operating staff.
2. Shotcreting work can be either plain or reinforced. Generally, a relatively dry mixture is
used, and so the material is capable of supporting itself without sagging and sloughing,
even for vertical and overhead applications.
3. The total thickness of shotcrete should not be less than about 75 mm so that a clear cover
of 25 mm to the additional reinforcement in the case of columns is ensured. The average
thickness of shotcrete should be 50 mm, if no additional reinforcement is provided.
Careful guniting ensures long service life of structures. However, it is essential to observe
several precautions at every stage in order to obtain the desired results and durable
structures.

47
1.5.2 (a) Materials for Shotcreting:

Cement, sand, coarse aggregate, water and admixtures are used in the Shot– Crete mix.
Ordinary Portland Cement, 43 Grade or 53 Grade will be used.

1.5.2 (b) Sand:

Sand for Shotcrete shall comply with the requirements of IS 383-2016 and graded evenly
from fine to coarse as per Zone II and Zone III grading of IS 383-2016. Well graded sand
as per either of the following grading can be used.

SAND

IS Sieve Designation Percentage by mass passing for

Grading – II Grading - III
10 mm 100 100
4.75 mm 90- 100 90- 100
2.36 mm 75- 100 85- 100
1.18 mm 55- 90 75- 100
600 microns 35- 59 60- 79
300 microns 8- 30 12- 40
150 microns 0-10 0-10
Sand should be free from deleterious substances and organic impurities.

1.5.2 (c) Coarse Aggregate:

The coarse aggregate when used shall comply with the requirements of IS 383-2016. It shall,
generally conform to one of the gradings given in the following table

IS Sieve Percentage by mass passing for aggregate of Nominal maximum Size

Designation
10 mm 12.5 mm 20 mm
(mm)
25 mm - - 100
20 mm - 100 90-100
12.5 mm 100 90-100 -
10 mm 85-100 40-70 20-55
4.75 mm 10-30 0-15 0-10
2.36 mm 0-10 0-5 0-5
1.18 mm 0-5 - -

48
1.5.2 (d) Water: Ordinary potable water with pH value not less than 6 and not more than 7.5 will be
used.

1.5.2 (e) Chemical Additives:

The following additives be used in the concrete mix in the ‘Dry Mix Process’ of
Shotcreting
Sodium Carbonate = ½ Kg per 50 Kg bag of cement
Sodium Aluminate = ½ Kg per 50 Kg bag of cement
Calcium Carbonate = 1 Kg per 50 Kg bag of cement
1.5.2 (f) Shotcrete Mix:
The water – cement ratio should be maintained within the range of 0.35 to 0.50 by mass.
Normally the following mix proportions would be adequate.

Sl. No Ingredients Used Conventional Mix Design with

Shotcrete Mix Admixture
1 Cement 450 kg / m3 420 kg / m3
2 Sand 1100 kg / m3 1050 kg / m3
3 Coarse aggregate (5 mm – 10 mm 500 Kg/m3 420 kg / m3
size)
4 Water Cement Ratio 0.42 0.4
5 Admixture (if any used) - 21 kg (Apcocrete shot-P)
6 Mix Proportion 1:2.44:1.11
7 Compressive Strength after 28 days > 25 N/mm2 51 N/mm2
1.5.3 Shotcreting Process:
The two basic shot creting processes are:
a) Dry mix process, and
b) Wet mix process.
Dry- Mix Shotcrete: Pneumatically conveyed shotcrete in which most of the mixing water is
added at the nozzle

Wet- Mix Shotcrete: Shot-crete wherein all ingredients, including mixing water are mixed
in the equipment before introduction into the delivery hose, it may be pneumatically conveyed
or moved by displacement

Comparison of features of Dry- Mix and Wet- Mix Shotcrete Processes

Dry- Mix Process Wet- Mix Process

49
 1. Mixing water instantaneously 1. Mixing water controlled at plant and
controlled at the nozzle by operator measured at time of batching
to meet variable field conditions
2. Longer hose lengths, if necessary 2. Normal pumping distances necessary

3. Limited to accelerators as the only 3. Compatible with all ordinary

practical admixture admixtures. Special dispensers for
addition of accelerators are necessary.
4. Use of air-entraining admixture not 4. Air entrainment possible. Acceptable
beneficial. Resistance to freezing resistance to freezing and thawing.
and thawing is poor.
5. Intermittent use easily 5. Best suited for continuous application
accommodated within prescribed of shotcrete
time limits.
6. Exceptional strength performance 6. Lower Strengths, similar to
possible conventional concrete
7. Lower Production rates 7. Higher Production rates
8. Higher Rebound 8. Lower rebound
9. Equipment maintenance costs tend 9. Equipment maintenance costs tend to
to be lower be higher
10. Higher bond strengths 10. Lower bond strengths, yet often higher
than conventional concrete

SFRC (9012-1978): Steel Fibre Reinforcement concrete is also used for stabilization in
application such as slopes or tunnelling, where it is finding difficulty to use conventional steel
mesh.

Concrete cubes prepared by directly guniting into 15 cm cube moulds may also be
used for day to day quality control tests. In such cases, the results should be correlated to the
results from tests of’ cubes made from panels . test panels, at least 30 cm square and 75 mm
thick shall be periodically gunned, and cores or cubes extracted for compressive tests and
visual examination.

1.5.4 Dos and Donot’s in Shotcreting

@nvv

DOS DONOT’S
1. Exposed reinforcement bars be 1. All oversize pieces shall be rejected by
cleaned free of rust / scales. screening, since they are likely to cause
Additional reinforcement is provided plugging of the hose
if and as warranted.

50
 2. Area kept ready for Shotcreting 2. Do not allow shotcreting unless all
surfaces shall be kept damp for unsound and deteriorated concrete be
several hours before shotcrete is removed and chipping done, wherever
applied but at the same time is not so necessary, or sand blasting done.
wet that there is excess of free water
on it.
3. At the end of each day work, or on 3. No square shoulders shall be left at the
stopping work for any other reason, perimeter of the cavity; all edges shall
the shotcrete shall be sloped off to a be tapered. The final cut surface shall be
thin edge and then the work shall be critically examined to make sure that it
resumed on next day after cleaning is sound and properly shaped. Improper
the surface. preparatory work is more often
responsible for failures of shotcrete in
repair work than any other single factor.
4. In shooting slabs, the nozzle shall be 4. Ordinary square construction joints are
held at a slight angle from the generally avoided in shotcrete
perpendicular so that rebound is construction because they form a trap
blown on to the completed portion for rebound.
from where it can be removed.
5. It is recommended that surfaces be
kept continuously water cured
for at least 7 days.

5.5 Quality Control for Shotcreting

Quality control of Shotcreting shall be done as per clause No. 8.12 of IS 9012: 1978
1. During the Shot-Creting operation, both the Construction and Quality Control Staff should
continuously inspect the site to check the materials, Concrete mix, Shotcreting equipment,
application of shotcrete and curing.
2. The finished surface should be sounded with a hammer for detection of any hollow
pockets due to lack of bond. If any such hollow pockets or other defects are found,
they are to be carefully cut out and replaced with the new shotcrete layer. The first
layer is also to be sounded with a hammer and remedial action taken for any hollow
pockets before commencing the application of the final layer.
3. Cubes or cores shall be taken from the panels for testing. The cores shall have a
minimum diameter of 7.5 cm and a length-diameter ratio of at least 1, if possible. The
specimens shall be tested in compression at the age of 7 or 28 days or both.
4. The cut surfaces of the specimens shall be carefully examined and additional surfaces
shall be exposed by sawing or breaking the panel when it is considered necessary to

51
 check the soundness and uniformity of the material. All cut and broken surfaces shall
he dense and free from lamination and sand pockets.
5. The test panels are fabricated by gunning on to a back form of plywood. A separate panel
shall be fabricated for each mix design being considered, and also for each gunning,
position to be encountered in the structure, that is, slab, vertical and overhead sections.
At least part of the panel shall contain the same reinforcement as the structure, to show
whether sound shotcrete is obtained behind the reinforcing rods. The test panel shall be
large enough to obtain all the test specimens needed and also to indicate what quality
and uniformity may be expected in the structure. Generally, the size of panel shall not
be less than 75 x 75 cm. The thickness shall be the same as the structure except that it
shall normally be not less than 7.5 cm.
6. The steel fibre reinforced concrete (SFRC- IS 9012: 1978) has gradually taken over
conventional shotcrete. Traditional reinforcement shotcrete is steel/ wire mesh, fixing
this mesh totally by manual work and it proceeds at a slow pace.

52
Typical plant layout for wet mix positive displacement equipment

53
6. TUNNELING

54
1.6 TUNNELING (IS 4880 {Part-I to V}, 5878 (Part-1 to 6), 15026)
Tunnels can be defined as underground passes made without removing the over lying
rock or soil. Water conductor system occasionally takes the form of tunnels through high
ground or mountains, in rugged terrain where the cost of surface pipe line or canal is expensive
and elsewhere as convenience and economy dictates.

The most commonly adopted method of tunnel excavation in India is the conventional
drilling and blasting method. And other method is by Tunnel Boring Machine.

1.6.0 UNDERGROUND EXCAVATION:

The tunnels are excavated by either drilling and blasting

1.6.1 DRILLING:

For driving a tunnel through rock, it is essential to drill holes for charging the
explosives. The drilling pattern should beas per the recommendation of Geologisteach
particular work as it depends on the texture and formation of rock, size and shape of the tunnel,
the drilling should be such as to ensure minimum over breakage and least amount of explosive
per unit volume of excavation. The diameter of hole at its deepest point shall be at least 6 mm
more than the diameter of the cartridge.

1.6.2 BLASTING:

Explosives - High explosives are used for tunnelling operations. The strength of high
explosives is expressed as a percentage of the strength of blasting gelatine.
Types of explosives used in tunnelling operations:
a) Blasting gelatine - It has the highest concentrated power and it is used for blasting
very hard and tough rocks.
b) Special gelatines 90 percent to 40 percent - These are characterised by gelatinous
consistency, high density, freedom from noxious fumes and good storage properties.
The requisite strength of gelatine may be selected to suit the actual rock conditions
which may vary from very hard to soft rock. For use at high altitudes, low freezing
types of gelatines may be used.
c) Ammonia dynamite- These types of explosives contain equal amount of nitro-
glycerine and nitrate of ammonia. They are made in strengths from 15 to 60 percent.
They are not so sensitive or so quick and shattering as straight dynamite. They are
recommended for soft rock.
d) Semi-gelatine - They contain nitrate of ammonia, gelatinised nitro glycerine and nitro-

55
 cotton. They are bulkier than the other varieties and come in only two strengths, 45
and 60 percent. They are water resistant and the fumes are not as bad as that of straight
dynamite. Because of their low density they are cheaper, and are recommended for soft
rock and limestone.

1.6.3 METHODS OF TUNNELLING:

i. Full face attack: In this method the entire cross sectional area of the Tunnel to be
excavated is attacked simultaneously. This is generally recommended for small size
Tunnels.
ii. Top Heading and Benching: In this method the Top Heading is excavated first. The
benching is removed slowly. This is suitable for a very less cross sectional area or
where rock is not of good quality. This method is most commonly used.
iii. Bottom Heading and Stopping: In this method Bottom Heading is made first and
overhead stop is removed later, suitable when section is large.
iv. Drift Method: In driving a large tunnel is may be economical to drive a small tunnel
called drift or a pilot tunnel prior to excavating the full face.

1.6.4 SEQUENCE OF OPERATION FOR CONSTRUCTION OF TUNNELS:

i. Marking tunnel profile,

ii. Setting up of drilling jumbos and drilling of holes,
iii. Loading the drilled holes with explosives and blasting,
iv. Defining and ventilating tunnel,
v. Checking misfires, if any,
vi. Scaling the loose material,
vii. Removal of the muck, and
viii. Guniting, Rock bolting and Erection of support system and lining if and when
necessary.
1.6.4 (a) Minimum Excavation Line (A-Line):
A Line within which no unexcavated material of any kind and no supports other than
permanent structural shall be permitted to remain.

1.6.4 (b) Pay Line (B-Line):

An assumed line (beyond A-Line) denoting mean line to which payment of

excavation and concrete lining is made whether the actual excavation falls inside or outside

56
 TYPICAL SECTION OF CONCRETE LINED TUNNELS SHOWING A- LINE & B- LINES

1.6.5 General Aspects for design in Tunnel lining:

Lining in tunnels technically an important component therefore lining operation requires

considerable study and careful planning
 Study of Geology of rock mass,
 Results of insitu tests for modulus of elasticity,
 Effective Cover, Poissons Ratio, State of stress,
 Seepage & Presence or Absence of Ground Level water table,
 Cavitations.
1.6.6 Loading Conditions:
Design shall be made for “Normal” Loading Conditions & Shall be checked for Safety under
“Extreme” Loading. The design loading shall be as follows:
a) External Rock Load
b) Self-Load of Lining
c) External & Internal Water pressure
d) Grout Pressure
e) Other Loads
To provide a proper bond between concrete and rock surface, grouting is recommended.

57
1.6.7 Types of grouting:

a) Contact grouting b) Consolidation grouting

It may be worthwhile to mention here that systematic investigation and

instrumentation give a lot of information before hand which could long way to solve many of
the varied tunnelling.

58
7.GROUTING

59
 1.7. GROUTING
(I.S. 11293 (Part 2) 1994 & I.S. 6066: 1994 (Part 1 & 2)
1.7.0SCOPE
The pressure grouting of rock, masonry, concrete dams with cement and with or
without suitable admixtures and fillers applicable to general grouting, consolidation grouting,
and curtain grouting shall broadly confirm to Indian Standard, IS: 6066-1994.
GENERAL:
A. The design requirements for adopting a grouting programme are as under. The parameters
will depend on the type of structure.
(a) Curtain Grouting:
i. To safeguard the foundation against erodibility hazard, and / or
ii. To reduce quantity of seepage.
(b) Consolidating grouting.
i. To reduce the deformability of jointed or shattered rock.
ii. Grouting the masonry dams to minimize seepage.
B. To reduce Quantity of Seepage:
a. For dams exceeding 30 m height, curtain grouting should be carried out when the
water absorption exceeds one lugeon.
b. For dams under 30 m, height, curtain grouting is to be carried out where the water
absorption exceeds 3 lugeon.
C. The depth, spacing and orientation of grout holes are to be related to the geological features;
for example, inclined holes should be preferred when the rock permeability is primarily
due to closely spaced vertical/ sub-vertical system of joints. It is sometimes necessary to
evolve a pattern of holes consisting of different sets of holes appropriate to each type of
discontinuity, such as bedding planes, system of joints and lava contacts.

1.7.1 GROUTING METHODS:

Rock grouting consists essentially of drilling a series of grout holes in rock and
injecting grout under pressure, which eventually sets in the opening and voids in the rock. The
drilling and grouting operations can be carried out either to the full depth in one operation or
in successive depths either by stage grouting or by packer grouting.
1.7.1 (a) FULL DEPTH GROUTING:

60
 In the full depth method, each hole shall be drilled to the full desired depth, washed,
pressure tested and grouted in one operation. This method shall be usually limited to short
holes, 5 m or less in depth, or holes up to 10 m that have only small cracks and joints with no
risk of surface leakage. In deep bore holes high grouting pressures shall be used to achieve
proper penetration of the grout at a spacing of holes shown in the drawing or directed by the
engineer-in-charge. As full depth grouting involves the risk of disturbance in the upper
elevations, it is not generally considered suitable for grouting deep holes. For grouting in
heterogeneous strata, where the nature of rock discontinuities is subjects to large variations in
relation to the depth, full depth grouting shall not be used and stage grouting shall be preferred
to packer grouting in such cases.

1.7.1 (b) STAGE GROUTING:

Stage grouting shall be conducted to permit treatment of various zones individually,

by grouting successively increasing depths, after sealing the upper zones. Stage grouting, in
descending stages, shall be carried out by adopting the procedure given below. Grouting shall
be done by drilling the holes to a predetermined depth and grouting this initial depth at an
appropriate pressure.
Grout shall be then washed from the hole prior to its final set (within 2-4 hours) and
the hole deepened for the next stage. Alternatively, the grout shall be allowed to harden and
re-drilling shall be carried out through the hardened grout and the holes extended to the next
stage. In another procedure called the one stage re-drilled method, which may be sometimes
used, grout is washed out within a small depth of the top of the stage being routed and only
one stage shall be re-drilled for proceeding to the next stage. In each of the above procedures
the cycle of drilling grouting- washing or re-drilling shall be repeated until the required depth
of the hole is reached.
For stage grouting, the connection at the top of the hole can be made directly to the
header or by sealing a packer at the top of the hole in the casing pipe. Alternatively, it is
sometimes advantageous to install a packer immediately above the stage that is being routed
in order to isolate the upper portion of the hole. Higher pressures can then be permitted for
grouting of the lower stage without causing upheaval in the higher stages.
Grouting with double packer shall be adopted where a few well defined seams or zones
exist and the packers can be seated above and below such zones. Rotary drilling method is
preferred when double packers are used.

61
 When packers can be seated and there is no risk of upheaval, grouting shall be carried
out with single packer in ascending stages.
However, in many cases packers may function yet grout may over travel and cause
upheaval in the zones above the section being grouted. At such places stage grouting in
descending order shall be adopted in case of badly jointed and fissured strata vulnerable to
upheaval.
In relatively compact rocks it may be more convenient to seal the packer at the top of
the stage being grouted. The hole shall then be washed, as soon as the period of initial set of
cement is over, to the entire depth of the hole up to the bottom of the stage in progress.
In strata vulnerable to upheaval, it may be necessary to allow the grout to set and form
a sheath around the hole in order to enable high pressures to be used in the lower portions of
the hole. In such cases, the washing and single stage re-drilling procedure shall be adopted.

1.7.2PATTERN AND DEPTH OF HOLES AND SEQUENCE OF GROUTING:

The pattern and depth holes shall be governed primarily by the design requirements
and the nature of the rock. When the purpose will be consolidation, the holes shall be arranged
in a regular pattern over the entire surface areas required to be strengthened and the depth
shall be determined by the extent of broken rock as well as the structural requirements
regarding the deformability and strength of the foundation. When the purpose will be
impermeabilization, the grout holes shall be arranged in a series of lines to form a curtain
approximately perpendicular to the direction of seepage. The depth of holes shall dependent
on design considerations as also on depth of pervious rock and the configuration of zones of
relatively impervious strata. For grouting with cement, 38 mm diameter holes may be used.
In long holes, the diameter at the top of holes may have to be larger than the final diameter at
the bottom of the hole to facilitate telescoping or to allow the wear of the bit.

1.7.3 PATTERN OF HOLES FOR CURTAIN GROUTING:

(a) SINGLE LINE GROUT CURTAINS:

Single line grout curtains are effective only in rocks / masonry / concrete having a
fairly regular network of discontinuities with reasonably uniform size of openings. In such
cases a curtain of adequate width can be achieved by grouting a single line of holes. In massive
rocks / masonry / concrete with fine fissures, uplift control shall be primarily achieved by
drainage and the grout curtain shall be used only as a supplementary measure to avoid
concentrations of seepage which may exceed the capacity of the drainage system. Single line

62
curtain may serve this limited objective in comparatively tight rock formations. In Single line
curtains a widely spaced system of primary holes, subsequently followed by secondary and
tertiary holes at progressively smaller spacing shall be drilled and grouted at spacing as shown
on the drawing or as directed by the engineer-in-charge. The usual practice of splitting the
spacing from primary to the secondary and secondary to tertiary phase shall be adopted. At
every phase of the grouting operation, the results of percolation tests and grout absorption data
shall be compared with the previous set of holes in order to decide whether a further splitting
of the space of holes in worthwhile. When no significant improvement shall be noticed either
in terms of decrease of the grout absorption or water percolation, careful review shall be made
of the rock/ masonry features, the nature of the rock/ masonry and its relations to the patterns
of holes. Sometimes it may be required to drill another line of holes at a different angle and
orientation than to split the spacing further. If the area is too limited, the setting time of the
grout becomes important since it is not desirable to drill too close to a freshly grouted hole.
Before pressure grouting is targeted, drilling of all the holes shall be
completed within a distance of 20 m of the hole to be grouted.
Depending upon initial investigation and strata conditions the spacing of primary hole
shall be decided. If the primary holes were spaced more than 6 m apartment secondary holes
should be drilled and grouted. On completion of primary holes spaced closer than 6 m or
secondary holes (when the primary holes are spaced more than 6 m), should the percolation
tests carried out in a few test holes indicate that further grouting of the area is necessary,
secondary or tertiary treatment, as the case may be, shall be carried out systematically
Thereafter in the whole area or in the particular section where the rock conditions are bad.
Similarly tertiary holes shall be taken over the whole area or the full length of the section
which requires the treatment. (Please refer the Drawing at the end of the chapter).

(b)MULTIPLE LINE GROUT CURTAINS:

In rocks with a wide range of sizes or openings, cavities and discontinuities which are
irregularly distributed, a single line curtain may not be effective. In such cases it may be
advantageous to use a multiple line curtain consisting of outer lines which are drilled and
grouted initially with thicker grouts. After completing the grouting of outer holes, intermediate
line, or lines, of holes may be drilled and grouted at comparatively higher pressure with thinner
grouts.

1.7.4 PATTERN OF HOLES FOR CONSOLIDATION GROUTING:

63
 The choice of pattern of holes, for consolidation grouting shall depend on whether it
is necessary to wash and jet the hole systematically. When washing has to be carried out, a
hexagonal pattern shall be preferred as this admits for flow reversal. When systematic washing
and jetting is carried out to remove all soft material in seams it may not be necessary to use a
primary and secondary system of holes.

When it will be desirable to test the efficacy of consolidation grouting by comparing

the grout absorption in primary and secondary holes a rectangular or square pattern of holes
shall be preferred. This shall be the case when the joints are irregular and relatively free from
in filling or it is not necessary to remove the materials filling the joints.

1.7.5 SEQUENCE OF GROUTING:

While carrying out grouting operations it is necessary to ensure that no hole is drilled
so close to a hole being grouted that inter connections develop. Spacing between primary holes
is generally so selected that the drilling could be carried out without interference from grouting
due to inter-connections from adjoining holes. Sometimes a situation arises when drilling of
upper stages of secondary holes may be in progress concurrently with the grouting of the
deeper stages of primary holes. In such cases, inter-connections would not be prevented if a
sufficient cover of rock is not available between the portion which is being grouted and the
zone in which the drilling of secondary holes in any zone of the foundation shall not be taken
up until sufficient cushion of already grouted stages of primary holes in the same area is not
available.
In multiple line curtains relative sequence of outer and inner rows shall also be strictly
followed.
When grouting in rock overlain by pervious soil it is necessary to complete grouting
of the contact zones of the rock and soil before commencing the grouting of the rock otherwise
the grout would escape into the soil and it may be possible to control or detect excessive
leakage.

1.7.6 GROUT MIXTURE:

@nvv

Masonry/Concrete grouting is usually performed with a mixture of cement and water with or
without additives.
The cement generally used shall be any of the following: -
i. Ordinary Portland - IS: 269-2015 or
ii. Portland Pozzolana - IS: 1489

64
 -(Part-I)-1991
-(Part-II)-1991
iii. Portland Slag - IS: 455- 1989
iv. Super Sulphated cement - IS: 6909-1990
iv. Sulphate Resisting Portland - IS: 12330 -1988

1.7.7 DRILLING AND GROUTING EQUIPMENT:

DRILLING EQUIPMENT:
The equipment shall be capable of drilling holes of size 38 mm to 75 mm diameter to the
required depths. The equipment shall be capable of providing a continuous water or air flush
of adequate capacity.
The various types of drilling equipment can be grouted as under.
(a) Percussive drilling equipment:
(i) Standard drifter or wagon drill;
(ii) Down the hole drilling equipment; and
(iii) Overburden drilling equipment.
(b) Rotary drilling equipment with suitable drive, that is, hydraulic, electric, diesel or
compressed air.
Percussive drilling methods are generally more economical in all types of rocks. For
deep holes it may be advantageous to use overburden drilling equipment. By virtue of the
separate rotation drive, greater speed and economy can be achieved, also by virtue of the
greater rigidity of casing tube combined with the drill rods, better control on inclination of
holes can generally achieved in the overburden drilling equipment. Down the hole hammer is
also capable of maintaining a better control on the inclination. However, the hammer may get
clogged when the drill cuttings form slush soft saturated strata cannot be removed by air
flushing.
During percussive drilling in stratified rocks where the resistance of the rocks is prone
to variation the holes may get curved and control on inclination may be lost. In such cases
guide tubes may be used for ensuring verticality of the holes of alternatively rotary drilling
may be used.

1.7.8 GROUT EQUIPMENT:

The equipment for mixing and grouting shall be capable of effectively mixing in
correct and specified proportions, agitation the grout and pumping to into the holes, in an

65
uninterrupted flow at the designated pressure it into the holes, in an uninterrupted flow at the
designated pressure up to at least of 5 kg/cm2 (75 psi) - 7 kg/cm2(100 psi). There should be
satisfactory arrangements for accurately measuring the quantity of water, cement and other
ingredients to be used. The agitator shall have paddles of suitable design and shape to keep
the mix in proper consistency till it is pumped into the holes. Standard equipments of approved
quality shall be used.
The mixing and conveying system shall be laid to provide sufficient capacity for a
heavy flow of grout. The mixer shall be in two compartments or parts so that grout could be
mixed one when that from the other is being pumped. In general, an uninterrupted flow of
grout shall be maintained and the grout conveyed from the pump to the hole through a pipe.
The mixer shall be placed as near the hole as possible and long pipe lines avoided. The
flow of grout into the holes shall be controlled by the pressure relief valve by passing and
returning to the mixer all grout not accepted by the hole at the desired pressure.
Proper pressure gauges shall be provided to measure the pressure of the grout pumped
into the hold. They shall be provided with diaphragms to prevent grout from getting into the
gauges and clogging them.

1.7.8 (A)SINGLE LINE SYSTEM:

The single line system consists of one grout supply line from the pump to the
grouting main-fold at the hole. the pressure gauge should be constantly monitored so that
pressure on the grout is regulated as long as grouting is in process. any desired increase or
decrease in the grouting pressure is obtained by changing the speed of the grout pump.

1.7.9 (B) CIRCULATION SYSTEM:

The circulation system required two pipe lines, a supply line from the grout pump to
the grout hole and a return line from the grout hole to the agitator/pump. By opening the
supply and grout hole valves, grout is forced into the hole as required. Pressure is maintained
by adjusting either the supply valve or the return valve, or both, so that complete control of
pressure is maintained at the hold. There should be a pressure gauge at the delivery end of the
pump. No grout is wasted when washing out the grout lines and close control of the grouting
operations is maintained. When directed electric or diesel drive pumps shall be employed, use
of a return line is necessary. Long supply lines shall be avoided to reduce the chances of

66
change in consistency of the grout and clogging. Field telephones are useful for
communication between the pump operator and the grout man at the collar.
The circulating system shall be so provided that the grout shall be kept circulating
continuously at sufficient velocity to prevent settlement of cement or clogging of pipe line
and fittings. The pump and the pipe line shall be flushed with clear water at frequent intervals,
to keep them clear. Deposits of grout in the pump, mixer etc. not removed by flushing shall
be removed, scraping, clipping etc. A fine screen capable of being readily removed, cleaned
and replaced would be desirable between the mixer and the pump. Proper
arrangement shall also be provided with equipment to stock adequate quantity of cement,
stone dust etc. likely to be required for the grouting.
After the grouting operations are completed for shift on the day, the remaining unused
grout mix shall be thrown away. Also, a mix not used up completely within one hour after
mixing or that which in the opinion of the Engineer has set or clogged shall be thrown away.
At no extra cost to the development. No payment shall be made on account of such wasted
labour, material etc.

1.7.10 DRILLING THE GROUT HOLES:

In such area as may be designated, holes shall be drilled size 38 mm to 50 mm in dia.
These will be spaced in rows spaced 3 meters apart or as specified in the drawings. The holes
specified for coring and exploratory drilling/ test holes shall be of 75 mm diameter or as
directed by the Engineer-in-charge.
Drilling in masonry, concrete or combination of these for local drainage or shallow
grouting shall also be done by percussion tube drilling method and paid for under the same
item as for the above. Grout holes both in the masonry or concrete shall be of varying depth.
The drilling in masonry or concrete above will be paid for at the same rate as for as drilling in
rock.
All holes will be drilled with the equipment of the type specified most suitable for the
particular job as approved by the Engineer-in-charge.
The depth and requirements of the drilled holes indicated are approximate and may be
altered as per actual needs, as found necessary.
The grout holes shall be drilled normal to the surface of masonry, or if so directed
inclined to the normal up to any inclination, in the direction as may be indicated without any
extra cost.

67
 At locations, where the leakages are excessive, masonry might require additional
drilling and grouting of any area which may have earlier been drilled, grouted and even
covered by concrete or masonry. The contractor shall comply with directions in this behalf.
The unit rate for all such holes also be the same as quoted in the bill of quantities and shall be
paid separately.
Re-drilling required, if any, in case of incomplete holes because of the contractor’s
failure to clean the hole before the grout has set or for any other reason shall be performed at
the contractor’s expense.
After the drilling of the grout hole has been completed it shall be temporarily capped
or plugged until it is grouted. Any hole that gets checked before it is grouted shall be opened
to the satisfaction of the Engineer-in-charge by and at the expense of the contractor.

1.7.11 CLEANING OF HOLES:

Before grouting and when a suitable small group of holes has been drilled, all but three
holes (consecutive or as otherwise considered suitable for the purpose of cleaning) shall be
closed temporarily at the surface. Water and air shall be pumped under pressure as determined
by the Engineer-in-charge into two holes and allowed to escape from the third until all possible
loose materials and mud etc., has been washed out of communicating seams or other passage
ways, if any. Combinations of three holes at a time shall thus be cleaned before applying any
grout into the holes. Suitable valves shall be used to permit alternate or continuous injection
of air and water and for quickly switching the flow from one hole to other so as to produce
turbulent action necessary to dislodge the softer materials if any. Water will be connected to
one hole and air to the other adjoining hole. The water and air connections shall be
interchanged at frequent intervals, to cause water to flow in every possible direction. The
operation should be continued till reasonably clean water emerges out of the holes. In general,
the pressure of water and of air shall be such as to maintain the minimum possible velocity
but sufficiently low to prevent heaving and movement of masonry. The normal maximum
pressure should be about 5 kg/cm2; higher pressure shall be used where so directed by the
Engineer-in-charge. The connected holes shall be blown clear of any detritus that might have
settled in the seams therein, washing shall be so timed as to immediately precedes the
grouting. Before the grouting of a hole under grouting in case they are found connected to the
hole under grouting. The cost of testing and preparing the holes and cleaning them shall be
deemed to be covered in the item of drilling.

68
1.7.12 PRESSURE GROUTING:

The proportion of cement and water will be as determined by the Engineer-in-charge.

Cement and water shall be of the same quality as specified under section IC sub- section A &
D. Payment shall be made for the quantities of material actually used as assessed by the
Engineer-in-Charge which shall be final and binding. The grout shall be applied at a low
pressure (as may be specified by the Engineer-in-Charge) initially and gradually but within
the time as may be specified by the Engineer-in-Charge, increased up to the maximum
pressure. It shall be maintained for minimum period of about 10 minutes thereafter. Care shall,
however, be taken to release the pressure immediately should there be signs of any movement
of any part or heaving of rock / concrete / masonry, which amongst other observations, be
indicated by sudden and erratic fall in pressure.
When grouting has just been commenced in any hole, if it is found that the grout has
been freely flowing too far to fast from the hole at low pressure, fine stone dust, or other
suitable material as may be approved by the engineer shall be immediately be added in order
to block the leakage at sufficient distance from the hole and thus localize the area to be grouted
for any particular hole or set of holes. As a hole approach refusal, the grout shall be
progressively thinned and grouting operation continued to refusal at the specified maximum
pressure maintained for period of minimum 10 minutes as stated in above paragraph.
The consolidation grouting of the foundations shall be done at pressure up to 5
kg/cm2or as directed by Engineer-in-charge.
Utmost care and precautions shall be taken to ensure that the dam masonry or concrete
is not damaged during the grouting. Any damage caused to the concrete or masonry or any
other element, material or structure in the dam or adjacent to it shall be made good by the
contractor at his own expenses and to the satisfaction of the Engineer-in-charge.

1.7.13 METHOD OF APPLYING GROUT:

It is always advisable to begin with a low initial pressure say 0.10 to 0.25 kg/cm2/m of
overburden, and build-up the pressure gradually. Initially the rate of intake may be 20 to 31
lit/min. In order to avoid the premature build-up of high pressure a general guideline should
be followed that the pressure should be raised only when the intake rate falls below 5 lit/min.
When surface leaks develop, pressure should be immediately reduced. Sub-surface cracking
may sometimes be indicated by an abrupt rise in the rate of intake after grouting at a constant
value of pressure for a considerable period.

69
 Grout mixture (ratio by weight of water and cement ranging from 5:1 to 0.8:1 is
recommended. It is only in exceptional circumstances that mixtures leaner that 10:1 need be
used. The choice of grout mixtures may be based on results of percolation tests conducted
prior to grouting.
The grouting of hole shall be continued till the hole or a combination of holes
takes grout mix at a rate less than -
Rate of grout intake Time in Minutes Pressure
0.03 cum. (1 cft.) 20 3.5 kg/cm2 (50 psi or less)
0.03 cum. (1 cft.) 15 3.5 kg/cm2to 7 kg/cm2
(50 to 100 psi)
The grouting shall, however be stopped when the pressure gauge registers sudden rise
or when other indications are seen of extension or upheaval or rock / masonry / concrete, under
the pressure being applied. After the hole has been grouted it should be closed by means of a
valve to maintain the grout under pressure in the seams or crevices into which it has been
forced.
After any hole is grouted, it should be examined if cement has settled, unduly with
water coming up, the amount of settlement depending on the proportion of mix used. Holes,
where such settlement has taken place, are to be cleaned of all soft sediment and grouted again
under pressure.
Shallow grouting (i.e. grouting not exceeding 15 m in depth) operations shall always
be started on the side of pattern so that the trapped air may be more easily forced out.
Grouting shall be continued until at the specified pressure the hole refuses to take grout
more than specified above. If for any reasons grouting operations must be stopped before a
hole has been grouted to refusal, clear water shall be kept running into the hole until grouting
is resumed.
1.7.14 TEST FOR GROUTING WORK:

The efficacy of the grouting operation may be estimated using one of the following methods:

1. Pre and Post grouting permeability values using percolation tests

2. Pre and Post grouting P-Wave velocities using seismic refraction/cross hole
geophysical techniques and changes in mass using gravity methods.
3. Pre and Post grouting deformation module using static methods.
4. Pre and Post measurement of pore water pressure

70
 1.7.15 RECORDS:

The information to be recorded daily is as follows: -

i. Result of the pressure test;
ii. Grouting feature, for example, curtain and consolidation;
iii. Date;
iv. Shift;
v. Name of Foreman;
vi. Grouting method, packer grouting or full depth grouting and stage whether first,
second or third;
vii. Hole station number or co-ordinates;
viii. Time grouting begun;
ix. Time of each change in mix, pressure, or pumping rate;
x. Name of Inspector;
xi. Time of hole completion;
xii. Total quantity of cement used for each pressure or mix charge;
xiii. Water-cement ratio at the start and each change thereafter;
xiv. Air pressure;
xv. Grout consumption and time required for consumption of each batch;
xvi. Pressure recorded at 3 min to 15 min intervals and on completion;
xvii. Rate of injection;
xviii. Cement washed;
xix. Total quantity of cement injected into the hole;
xx. Reason for abandoned holes (if any);
xxi. Number and depth of holes left for re-drilling; and
xxii. In addition, the inspector should record under 'Remarks' any change or affecting the
grouting operation; such as 'tight hole', 'no leakage', 'had leakage', 'leaks caulked' 'grout
pump down', 'hole completed' and so forth.

1.7.16 REPORTS:
In order to facilitate control and planning of grouting operations, reports should be
prepared at regular intervals to summarize important observations and data. It serves no useful
purpose to maintain elaborate records unless they can be complied in such a form that

71
significant trends can be determined regarding the efficacy or otherwise of the grouting
operations. In the absence of such reports timely action, would not be possible and procedures
which may be ineffective or unsuitable may be continued indefinitely. These reports may
consist of:
a. a hole-wise register of drilling, water tests, routing and inter connections.
b. for consolidation grouting -a plan showing grout hole stages and grout intake.
c. For curtain grouting - an 'L' section showing driving stages and grout intake.

1.7.17 GROUTING MUST BE DONE IN THE PRESENCE OF THE ENGINEER-IN-

CHARGE OR HIS REPRESENTATIVE:

Whenever pressure grouting is to be done, the contractor will give due notice thereof
to the Engineer-in-charge to enable him or his authorized representative to be present during
the grouting operations which will always be done in his presence.

1.7.18 FINISHING:

The grout mix that might flow out or otherwise get spilt on the concrete or masonry or
other surface shall be removed expeditiously without allowing any time for the grout to set on
any of the aforesaid surface. After the grout has set, the grout holes shall be plugged with
cement mortar in the proportion of one to two by volume and the surface finished smooth in
line with floor at that location.

1.7.19 CALIBRATION OF PRESSURE GAUGES & WATER METERS ETC:

The pressure gauges and water meters shall be got calibrated by the contractor at his
cost, for their accuracy from time to time as may be directed by the Engineer-in-charge. The
contractor shall produce necessary test certificate for such calibration. The pressure gauges
and water meters which have been duly tested and calibrated shall only be used for grouting
and testing holes.

1.7.20 MEASUREMENT AND PAYMENT:

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 The exploratory holes shall be measured and paid, for in actual linear meter of depth
drilled or as directed by the Engineer-in charge whichever is less and shall include drilling
taking water intake test in stages under pressure wherever specified.
Drilling shall be measured for actual depth of drilling and paid to for at the unit price
tendered for the relevant item in the bill of quantities. These unit prices shall include drilling
of holes and maintaining the hole free from choking until grouted, washing and preparing the
holes for grouting, and all works incidental thereto.
Measurement and payment for pressure grouting shall be made on the basis of cement
actually forced into the grout holes. All wastage due to any cause shall not be paid for.
Payment for grouting shall be made at the unit price per metric tonne of cement
tendered in the bill of quantities and shall include all material, plant and labour required for
the grouting operation.

1.7.21 Test Grouting:

Test grouting of at least 10% if the holes already grouted shall be carried out to ensure
that no gap/void/cavity remains unfilled. The holes with high consumption of grout during
initial grouting and those with high water intake but less consumption of grout shall be
specially included for test grouting along with other holes.
Daily Records of Grouting Operations:
Daily Records of grouting operations along with the approval of Engineer in charge
shall be maintained as specified in I.S. Codes.

Grouting Patterns of Grout Holes

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 8.BARRAGES

1.8 BARRAGE

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Barrage is a barrier with low crest provided with a series of gates across the river to regulate
water surface level and pattern of flow upstream and other purposes, distinguished from a
weir in that it is gated over its entire length and may or may not have a raised sill.Barrages
and weirs are constructed for diverting water from rivers for various uses like irrigation,
navigation, power generation and drinking/ industrial water supply. The structure may be
either of masonry or plain concrete or reinforced concrete, depending on the nature of
foundation encountered, availability of construction materials, dewatering problems,
economy of construction, etc.,

Generally, the river discharges are widely fluctuating and operations/regulation of

the gates have to be modified from time-to-time on the basis of river behavior, morphological
changes, etc. Barrages are not storage structures and the waterway is designed according to
design flood without any moderation. As such, during the life of barrage, it is seldom that all
the gates are required to be opened fully. Gate operations, particularly during low floods are
a key factor for flushing of sediments and prevention or alteration of shoal formation on the
upstream and downstream of the barrage.

Basic Components of the Barrage

 Upstream protection arrangement

 Crest
 Stilling Basin
 End sill
 Downstream protection arrangement
 Piers
 Divide Walls
 Fish Pass
 Under sluices
 Abutments
 Flare out wall
 Flank wall
 Guide Bunds
 Return Walls
 Afflux bunds
 Cutoffs

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  Intake Regulator with similar arrangements

1.8.1 SEQUENCE OF CONSTRUCTION OF BARRAGES

The following sequence of construction should generally be adopted at the various
stages of the construction work as per IS:11150-1993
1) Temporary Access
Temporary Access Bridge should be provided for transport of man, materials,
and equipment whenever necessary.
2) Coffer Dam
The layout of Coffer Dam enclosure should be decided on the site conditions,
nature of river course, and programme of works for the season [Reference may be
made to IS 9795 (Part I): 1981 and IS 10084 (Part 1): 1982
3) De-watering
The following points should be taken care of while dewatering
a) After completing the excavation above the water table dewatering of the
foundations should be commenced by well points/open pumps/deep well pumps
and the water table progressively lowered.
b) In sandy soil well point systems may be suitable for dewatering. In silty clay
foundations strata open pumps and/or deep well pumps may be suitable. If an
impermeable compact shingles-cobble layer is sand witched between sandy
layers in. the depth to be excavated, deep-well pumps with strainer throughout
the depth of the tube well will be suitable.
c) The bore hole details indicating the foundation strata, soil characteristic namely,
grain sizes, distribution, relative density and permeability should be examined
before deciding on the system of dewatering.
d) The preliminary requirements of dewatering pumps should be based on the
inflow to the work area, calculated on the basis of permeability of the strata and
closeness of the water source/ sources.
e) The designs, installation and operation of dewatering system should be in
accordance with IS 9759: 1981.
f) During dewatering operation, care should be taken to ensure that there is no
removal of fines from the substrata that may weaken the foundation.
g) Any seepage of water from the foundation at local points or springs should be
taken care of properly so that there is no piping of the foundation material.

76
4) Excavation
Excavation of the foundation to the barrage profile is to be made either
manually or by machines in reasonably dry condition. During excavation, water table
should be maintained at a lower level than the level at which excavation is being done.
The excavated soil should be disposed of either manually or by machines, to suit site
requirements. In case, machinery is employed for excavation, final excavation of the
lowest layer should be done manually to the specified depth.
5) Cut-off walls
a) Sheet pile cut-off walls in non-bouldery reaches (IS:2314-1986)
The sequence of construction should be as follows,
 After excavation to the final profile or very near to the final profile is
completed, driving of sheet piles for cut-offs may be started.
 Sheet piles should be driven vertically in pairs, with bulb forward, by
means of cranes, or pile frames using drop hammers, single/double acting
hammers or vibro sinkers depending on the availability and suitability of
machines with respect to soil characteristics of the barrage foundation. It
may not always be possible to drive the sheet piles vertically plumb.
Whenever the piles lean beyond the permissible limit, suitable taper piles
should be provided to correct the verticality.
 Welding of piles prior to driving or welding in situ to make up the required
length may normally be permitted. Driving of welded sheet piles of more
than 8 m length is, however, not considered safe as weld may give way
under high driving stresses.
 Cross-sheet piles under double piers in the raft type design, connecting the
upstream and downstream cut-offs and sheet piles near the junctions should
be driven with proper precautions, as regards the verticality of piles.
 Sheet pilling for abutments, return walls and flared out walls should be
taken up simultaneously, wherever possible, to ensure easier and vertical
driving.
 Sheet piles if used for temporary protection works may be permitted to be
left in place if their extraction is likely to endanger the safety of the
structure, due to disturbance of foundation-strata during extraction.

77
 However, after completions of the work, the head of the piles are to be cut
off up to bed level.
 Wherever seals are provided and are to be joined to the sheet piles, it should
be carefully done by welding and brazing or bolting, as necessary.
 Since sheet piles are designed to have hinge action at the top, it should be
ensured by provision of tar paper wherever two pile rows are provided side
by side. Cork mastic filter on top may be provided to take care of uneven
heights and hinge action.
b) Cut-off walls in bouldery strata
The barrage founded on bouldery strata should be constructed either with
concrete diaphragm wall cut-off or installation of steel sheet pile cutoff in
preformed trenches back filled with sand. The sequence of construction should be
as under,
Concrete Diaphragm wall Cut-off:
 Excavation of the trench for the concrete diaphragm through sub-soil
should be done with suitable trenching machine capable of ensuring that
the width of trenches excavated should conform to the thickness of
diaphragm wall.
 The excavation of the trench should be carried out by means of bentonite
slurry circulation method to enable tremie concrete for construction of
diaphragm cut-off. The sides of the trench should be suitably maintained
before and during the concrete to prevent any caving-in.
 After formation of the trench, reinforcement cage in accordance with
design requirements and predetermined panel lengths should be lower into
the cut-off trench.
 The concrete’ of requisite strength should be placed in such a manner that
the concrete displaces the slurry and mixing of concrete with slurry does
not occur. The tremie should be watertight and sufficiently large to permit
free flow of concrete, and all precautions should be taken to get good
quality of concrete.
 The placement of concrete should continue without interruption until the
concreting is completed up to required elevation in the section or panel, of
the wall under construction

78
  To connect the joints between the wall panels, shoulder pipe or any other
method as recommended should be used. The joints between the concrete
diaphragm panels should be pressure grouted with cement grout as
considered necessary, so as to ensure a continuous unbroken cut-off.
Sheet pile cut-off in preformed trenches backfilled with sand:
 A trench along the sheet pile cut-off line of suitable width (generally 600
mm wide) should be formed by bentonite method.
 The preformed trench should be back-filled with locally available sand by
replacing the bentonite slurry and the bentonite washed out by compressed
air and waterjet injected in the backfilled sand.
 Steel sheet pile cut-off should be installed in the preformed trench, in
accordance with sequence mentioned above.
Secant Pile cut-off Wall:
i) Construction of Guide wall:
Guide wall is two parallel concrete walls constructed along the side of the piles
as a guide to the piles. Guide walls are constructed in-situ typically as lightly
reinforced concrete elements. Guide walls maintain the horizontal alignment and wall
continuity of secant pile while they provide support for the upper soil layers during
auguring. This temporary support is important as the guide walls help to guide the
piling rig vertically and aid in positioning the secant pile. In addition, this helps to
maintain the levels of drilling fluids during the boring at top few feet above ground
level.

ii) SECANT PILE

The construction sequence for the secant piles will be to bore and cast the
primary piles in the beginning followed by secondary piles (reinforced). The
secondary piles are bored after 1-2 days of pouring of concrete in primary piles.

A. Primary Pile

79
 The Primary/soft pile will be constructed first as the primary piles for the
secant pile wall. The primary pile will be filled with the specified strength of mass
concrete without any steel reinforcement.
B. Secondary Pile
The secondary pile will be constructed in between the primary piles and
overlap with the primary piles with the specified strength of concrete after the
reinforcement cages are lowered into the bored hole. The secondary pile formed
by cutting into the primary piles to form the interlocking joint by using the
specified boring tools. The boring process for the secondary pile shall only
commence upon initial set of the primary piles, i.e. 1-2 day on concrete completion
of the primary piles.

The sequence will be as under

 Drilling of the Primary Piles, 1,3,5,7, etc...

 Concreting of Primary piles.
 Drilling of the Overlapping Secondary (Reinforced) Piles, 2, 4, 6, etc...
 Install the Steel Cage.
 Concreting of Secondary piles.

iii) Setting up of each Pile point

Survey will carried out from main grid lines and pile points shall be marked
with iron pegs using total station.

iv) Setting of Rig

Initially all the piling area shall be barricaded with barricading boards to isolate
the working area. The rig shall be positioned at pile point with required boring tool
attached to Kelly. Verticality of mast will be checked using controls in the operator's
cabin. Kelly verticality will be checked using spirit level.

v) Pile Boring

The diameters of augers & buckets will be measured and recorded. The boring
will be conducted using hydraulic rotary piling rig. For boring through soil strata Soil

80
 auger/bucket will be used. When rock is encountered, rock auger & rock bucket
replaces the soil auger & soil bucket and boring continues until termination depth.

vi) Stabilizing the borehole:

Bore hole will be stabilized by temporary casing for top 3m to 4m and

bentonite as drilling fluid. The required quantity of bentonite shall be prepared with
fresh water be air agitating system. The properly mixed bentonite shall be stored in the
storage tank and it shall be used immediately.

The properly mixed bentonite shall satisfy the following properties at all times,
the values given below are typical and needs to be finalized from site trail only. The
density of the bentonite shall be checked before pumping into the borehole. All the
time bentonite level shall be maintained to 2 to 2.5m above the water table.
Annexure -D of IS:2911-2010 Part.1 Sec.2

Description Requirements Bentonite Requirements Bentonite

slurry details @ storage slurry details @ Pile bore
tank hole
Density (Kg/m3) 1.03-1.10 <1.12
Marsh cone value (viscosity) 30-90 <90
(Sec)
PH Value 9-11.5 <11.5

At the termination level, the pile bottom will be cleaned using cleaning bucket
and the final depth measurement will be recorded before lowering reinforcement and
concreting operation.

vii) Preparation of Reinforcement cage

 Steel reinforcement cages shall be fabricated in accordance with approved

drawing.
 Reinforcement used shall be made up into stiff cages using stiffener rings at
suitable intervals and duly tack welded to main reinforcement at suitable
points to withstand handling without much distortion or damage.
 They will be placed in position and be supported away from the sides of the
pile shaft by means of 75 mm thick spacer blocks

81
  The reinforcement shall extend for full length of the pile and shall project 60
times bar diameters above the cut off level or as specified in the drawing
 Only circular concrete cover blocks threaded on to the helix shall be used for
ensuring the specified cover.
 If it is a primary pile, there is no need of reinforcement cage in borehole

viii) Casting of Primary Pile or Plain Concrete Pile (P):

 Approved concrete design mix shall be used for casting of primary pile.
 Concrete of required grade at the required slump as per 1S 456 will be placed
in the pile bore by tremie method
 The tremie pipe shall not be less than 200 mm. in diameter and shall be large
enough to allow a free flow of concrete and strong enough to withstand the
external pressure of the water in which it is suspended, even if a partial
vacuum develops inside the pipe.
 The top section of the tremie shall have a hopper large enough to hold one
full batch of the mix. The joint in tremie shall be watertight.
 The tremie attached to the hopper will be lowered to the toe of the pile and
raised minimum 150 mm off the bottom to allow concrete to flow.
 The first charge of concrete shall be placed in hopper over the sliding plug at
the bottom of hopper.
 The charge will be adequate in volume to ensure flushing action to prevent
mixing of water or drilling mud and concrete.
 Once concrete is flowing, tremie pipe will be gradually raised ensuring that
the tremie pipe is always embedded at a minimum of 2m (approximate) into
the concrete.
 Pouring of concrete will continue until the concrete level is above the pile
cut-off level as per technical specification to permit removal of all laitance
and weak concrete and to ensure good concrete at cut off level for proper
embedment in to the pile cap.
 Normally concreting of piles shall be uninterrupted and continuous operation
in exceptional case of interruption of concreting. But which can be resumed
within 2 hours the tremie pipe shall not be taken out of concrete. Instead, it

82
 shall be raised and lowered slowly from time to time to prevent the concrete
around the tremie pipe from settling.

ix) Construction of Secondary Pile

I) Boring of Secondary Pile (S):

After the completion of initial set of primary piles as explained in the

sequence of secant piles, the boring and flushing for secondary pile starts. The
Secondary Pile will be constructed in between the primary piles and overlaps with
primary piles.

II) Placing of reinforcement cage in Secondary Pile (S):

Prefabricated reinforcement cage of secondary pile will be lowered into

secondary pile borehole with the help of lifting crane. The cage will be positioned in
borehole by using circular cover blocks and lifting hooks.

III) Concreting of Secondary Pile (S):

After positioning the cage, borehole will be flushed with drilling mud
(Bentonite), once properties of flushed bentonite attained as per requirement, tremie
will be lowered for concreting the secondary pile. The concreting will be done in the
same sequence as that of the primary pile.

c) Foundation preparation and Instrumentation

 Once the cut-off walls on upstream and downstream sides of the barrage
are installed and pile caps partially completed, the foundation surface
should be properly levelled, dressed and consolidated.
 The foundation should not contain loose pockets or materials and they
should be watered and compacted to the specified relative density, if
necessary, by vibro-rotation technique
 Clay pockets should be treated as specified by the designer. It has to be
ensured that proper drainage arrangements in the foundation according to
the designs including inverted filter, wherever indicated, are provided and
concreting work is taken up
 Piezometers, pressure cells, Soil stress meters, tilt meters and other
instrumentation as specified should be installed. Care should be taken to protect
these instruments and their connections during subsequent operations.

83
1.8.2 Concrete
Batching, mixing, placing and protection of concrete should be done in
accordance with IS 456: 2000. Block-out should be provided for embedded parts m
accordance with drawing. The following sequence of operations should be adopted for
various concrete items.
a) Pile Caps:
 Pile cap for sheet piles should be laid with the concrete floor. However,
pile caps may be constructed in advance to serve as a retaining barrier for
taking up concrete apron blocks.
 Normally the pile caps are taken deeper than foundation level and it may
be necessary at times that concreting of portion of pile caps may have to
be done in underwater condition. This should be done in accordance with
IS 456: 2000. The balance portion of the pile cap should be done along
with the main structure taking proper care for treatment of the joint.
 Dowel bars or if necessary, metal sealing strips should be provided for the
joints between the pile caps and the barrage floor. The sealing strip, if
provided, should be properly and securely braced with the sheet piles and
the concrete should be carefully placed against the faces of the vertical
joints and the sealing strips so as not to disturb the water seal
 In case of bouldery strata, where diaphragm wall cut-off is provided,
similar arrangement of dowel bars or sealing strip should be provided to
seal the joint between the cutoff wall and the barrage floor. Rubber, PVC
or metal sealing strips should be provided and proper precautions should
be taken while concreting, so as not to disturb the water seals.
b) Barrage Bays, Silt excluder and Piers:
 If it is envisaged to place the concrete in barrage bays and piers by means
of cranes (Boom Placers), the cranes may be located on the upstream and
downstream of barrage.
 The sequence of concreting of various lifts, starting from downstream end
of the barrage and with continuous pour in suitable layers, or as specified
by the Engineer-in-charge.
c) Abutments and flared out walls:

84
  In case of pile foundations, the piles should be driven to the founding
levels and pile caps and foundation raft should follow.
1.8.3 Divide wall well foundations
The wells should be sunk to the founding levels and the work of barrage bays
on either side of the divide wall should be taken up after construction of well including
well-caps.
1.8.4 Cement concrete/ Colcrete blocks
 In case of cast in-situ blocks, alternate blocks should be concreted or a proper
pattern of concrete sequence should be established for economical use of block
shuttering. The formwork should be so designed that when it is stripped off,
the required gap is formed for filling filter material. For casting the upstream
protection blocks shuttering oil should be applied on the surface of the blocks
already cast.
 Colcreting of cast in-situ blocks should be permissible. For colcrete blocks,
aggregates should be placed into shuttered boxes of requisite sizes and hand
packed before colgrouting. The proportion of colgrout should be as specified
by Engineer-in-charge.
 To facilitate speed of construction. Pre casting of blocks may be allowed.
1.8.5 Miscellaneous works
a) Construction of Bridge
 The bridge over the barrage should be either in reinforced concrete or
prestressed concrete and should be constructed in accordance with
approved design and drawings.
 The sequence of construction of bridge spans over the completed barrage
piers should be synchronized with the programme of completion of
barrage piers, from either bank, and will be mainly dependent on the plant
set-up and other infrastructural facilities at site.
 It may be a possibility in major barrages with large number spans, to take
up construction of bridge over the completed piers from one end as a
parallel activity while the work on the balance barrage bays and piers is
under construction. While the main barrage and bridge over the barrage
are being constructed concurrently, proper arrangements for conveying

85
 and feeding of concrete to various placement points should be made to
facilitate speeding-up of work.
b) Erection of Gates and Hoists
 Detailed planning of various activities of erection of hydro mechanical
equipment should be made so that works on other items under progress do
not hamper.
 The Erection of gates and hoists can be started after completion of the
bridge over the barrage
 Layout of the crane-track for the crane to be utilized for erection of hydro-
mechanical equipment should be suitably planned so that the other
activities on the construction of bridge go on smoothly and the portion of
the road bridge is also available for haulage of men, materials, equipment,
etc. for other works on barrage.
c) Backfill of Retaining Structures
 Backfill comprising of earth or rock fill should be placed at locations
indicated in the approved drawings
 All backfill materials should be graded to lines and grades, and should be
drawn from the excavated materials as far as possible
 The compacted backfill should be done in layers not exceeding 225 mm
with approved type of pervious soil. The optimum moisture content and
relative density should be in accordance with the approved
design/specifications.
d) Construction of approach banks, guide bunds, afflux bunds, etc.
 The work on the construction of approach, afflux and guide bunds may be
taken up from the farther ends to suit the construction programme of the
main barrage.
 After completion of retaining structures, such as abutments, return walls
and flare out walls of the barrage to the required levels. The embankments
of approach banks, guide bunds and afflux bunds should be completed and
keyed to the main barrage structure according to the approved drawings.
6) Head Regulators
The construction sequence of head regulators should be similar to the
Construction sequence of barrage.

86
 The Following IS Codes are used during the Design and Construction of
Barrages.
1. IS 11130-1984: Criteria for Structural Design of Barrages and weirs
2. IS 11150-1993: Construction of Concrete Barrages
3. IS 6966-1989: Hydraulic Design of Barrages and weirs-Guidelines
4. IS 7720-1991: Criteria for Investigation, Planning and layout for Barrages and
weirs
5. IS 10751-1994: Planning & Design of Guide Banks for Alluvial Rivers
6. IS 12892-1989: Safety of Barrage & Weir Structures-Guidelines
7. IS 7349-2012: Barrages and Weirs- Operation and Maintenance-Guidelines
8. IS9296-2001: Guidelines for inspection and maintenance of dam appurtenant
structures
9. IS 456-2000: Code of practice for Plain and Reinforced Cement concrete
10. IS 269-2015: Specifications for Ordinary Portland Cement
11. IS 1489-1991 : Specifications for Portland Pozzolona Cement
12. IS 1786-2008: Specifications for High strength deformed steel bars and wires for
concrete reinforcement
13. IS 516-1959 (Ra-2004): Method of test for strength of concrete
14. IS 383-2016: Specification for Coarse and Fine Aggregate from natural sources
for concrete.
15. IS 2386-1963 Part 1to 08: Method of tests for Aggregate for Concrete
16. IS 2720-1974 Part 28-Method of test for soils, Determination of Dry density by
sand replacement method
17. IS 2720-1974 Part 29-Method of test for soils, Determination of Dry density by
Core cutter method
18. IS 1498-1970: Classification and identification of soils for general engineering
purposes
19. IS 14248-1995: Guidelines for instrumentation of barrages and weirs
20. IS 2911-1-1;2010: Design and Construction of pile foundations, Part1-Concrete
piles Sec-1, Driven Cast in-situ concrete piles
21. IS 2911-1-2;2010: Design and Construction of pile foundations, Part1-Concrete
piles Sec-2, Bored Cast in-situ concrete piles
22. IS14893-2001: Nondestructive Integrity testing of piles- Guidelines

87
IS CODES for Gates (Hydro-Mechanical works)
1) IS 2062-2011: Hot Rolled Medium and High Tensile Structural Steel
2) IS 8500-1991: structural steel – micro alloyed (medium and high strength
qualities)
3) IS 6527-1995: Stainless steel wire rod [Alloy Steels and Forgings]
4) IS 1570 Part-5-1985: Schedules for Wrought Steels, Part 5: Stainless and Heat-
resisting Steels
5) IS 2004-1991: Carbon steel forgings for general engineering purposes
6) IS 1030-1998: Carbon steel castings for general engineering purposes.

88
9.PRESSURE MAINS

89
 1.9 PRESSURE MAIN (MS PIPES)
(IS 228, IS 3803, IS 1916 and IS 3589)
@nvv

The water conductor system in a Lift Irrigation Scheme is mainly through pipes. These
pipes generally are manufactured in a yard, near to the reach of pipe laying. The pipe is
manufactured by welding plates which form number of longitudinal and circumferential weld
joints. Later these pipes will be transported to a site and joined by welding after placing in the
position to form the pipe line. So, the pipe in the yard and pipe line at the site should be tested
according to the agreement conditions and relevant IS Codes.
Plates from the manufacture has to be tested for the Chemical Properties and
Mechanical Properties to ascertain the durability and serviceability of the plate for Steel
Conforming to the specified grade in accordance to the agreement conditions.
1.9.1 SEQUENCE OF OPERATIONS
The process of fabricating a pipe involves a series of following procedures for a
durable and long-lasting water conveyor system.
1) UN-loading and stacking of plates.
2) Marking and edge preparation.
3) Rolling of Plates
4) Fit Up
5) Welding
1.9.2 UN-loading and stacking of plates.
The plates are to be unloaded from the truck by using hook and sling by hydra
crane or gantry of suitable capacity. The plates will be placed on the ground level with proper
wooden packing.
Each plate is checked for its identity with respect to Plate No, size, weight from mill
marking/sticker pasted on each plate and noted in supply register. The plate is measured for
its width, length with tape and thickness with vernier calipers and visually checked for surface
appearance and edge quality.

Reference to Standard Specifications and Tolerance Limits

1. As Per IS0 7452-1984
2. Agreement conditions and Concern Higher authority Memo, if any

90
1.9.3 Marking and edge preparation.
The cut size of the plate will be exactly marked and diagonal will be checked
correctly. Chalk marking and all corners of the marking will be center punched. The pug
cutting rails should be set along the marking with the help of a ‘T ’gauge. Set the angle of pug
cutting way according to the IS code or agreement conditions a template can be made for
checking during and after cutting. Start cutting with “NEUTRAL FLAME” and ensure smooth
cutting of plate. The bevel cutting will be done wherever the necessary side of the plates. After
cutting the burs and unusual materials will be removed by the AG7 Grinding machine. Then
it may lift and to be shift to the rolling yard.
Reference to Standard Specifications and Tolerance Limits
1. IS 3589:2002, IS 2825-1969.
1.9.4 Rolling of Plates
Make stitch weld abutted side and pull the shell out after opening the swing arm. Set
the plate exactly perpendicular to the roller and feed the plate inside the roller. Radius check
should be done of each shell by template during plate bending. Make pre pinching according
to the template to the diameter of pipe. The pre pinching will be done accordingly to the both
sides of plate. Start rolling with appropriate pressure throughout forward and reverse till two
side of plate come in to contact. Now the rolled shell can carry to the fit-up yard.
Reference to Standard Specifications and Tolerance Limits
1. Check the I.D Inner diameter of the shell with template and measuring tape so
that we can bring accurate dimensions.
1.9.5 Fit Up
The independent shells will be kept on the fit-up bed (i.e bed made of rails). All
longitudinal seam (L.S.) will be kept proper staggered 180 degree (at least above 90 Degree).
Do fit up by using Land wedge and uniform root gap will be maintained. According to length
of pipe, the shells will made fit up. Then the pipe will be rolled to saw welding bed with the
held of hydraulic power pack.
Reference to Standard Specifications and Tolerance Limits
1. Shell to shell fit up gap do not exceed 1 mm (LS & CS).

1.9.6 ARC Welding

At fabrication yard, welding is performed according to the agreement conditions. The
pipe will be placed over the welding rollers smoothly and rated RPM will be set on rollers for

91
circumference joint. Give proper earth connection and make saw welding outer and inner with
suitable wire and amps. Visual examination shall be done to check the weld penetration and
overlapping. Check the welding after removal of slag and avoid puncture of welding. Set a
start plate for starting weld joint and check the finishing of welding. Each and every pipe
should be inspected for inside and outside weld as well as surface defects. Surface/weld
defects are marked by chalk/crayons for necessary rectifications. All observations shall be
recorded in log sheet/ register.
Reference to Standard Specifications and Tolerance Limits
1) IS 3613, IS 7280, IS 814.
1.9.7 TESTING OF PIPE
After the fabrication of the pipe, it is further checked as the plate itself may have
manufacturing flaws, and to detect such flaws, the material and the effectiveness of welding
have to be checked with following test procedures and tests are conducted as per the frequency
prescribed in the agreement.
1) Check for Ovality
2) Dye-Penetration Test
3) Ultrasonic testing
4) Radio-graphic testing
5) Hydro Testing
1.9.8 Check for Ovality:
Ovality shall not exceed 1 % of the specified outside diameter for pipes having
diameter to thickness ratio not exceeding 100. where the diameter to thickness ratio exceeds
100 the tolerance on ovality if not specified and should be agreed between the manufacturer
and the Purchaser.
Reference to Standard Specifications and Tolerance Limits
1) AS per IS 3589-2001.
1.9.9 Dye- Penetration Test:
Liquid penetrant processes are non-destructive testing methods for detecting
discontinuities that are open to surface. Surface discontinuities, such as cracks, seams, laps,
cold shuts and laminations, are indicated by this method. By using Surface Cleanser,
Developer and Penetrant.
A suitable liquid penetrant is applied to the surface of the component under
examination and is permitted to remain there for sufficient time to allow the liquid to penetrant

92
into any defects open at the surface. After the penetrant time, the excess penetrant, which
remain on the surface, is removed. Then a light coloured, powder absorbent called a developer
is applied to the surface. This developer acts as a blotter and draws out a portion of the
penetrant which had previously seeped into the surface openings. As the penetrant is drawn
out, it diffuses into the coating of the developer, forming indications of the surface
discontinuities or flaws.
Reference to Standard Specifications and Tolerance Limits
1. IS 3658:1999 Code of Practice for Liquid Penetration Flaw Detection
(second revision). Reaffirmed- May 2014.
1.9.10 Ultrasonic testing
It is a Non- Destructive Testing techniques based on the propagation of ultrasonic
waves in the object or material tested. In UT applications, very short ultrasonic pulse-waves
with centre frequencies ranging from 0.1-15 MHz, and occasionally up to 50 MHz, are
transmitted into materials to detect internal flaws or to characterize materials.
A pulse echo type of ultrasonic instrument shall be used for inspection of welds by
direct contact. This method is applicable to material thickness over 5 mm. This instrument
shall be capable of operation at frequencies over the range of at least 1 MHZ to 5 mHz and
shall be equipped with a stepped gain control in units of 2.0 dB or less. Ensure that the device
is having required frequency before testing. Ultrasonic instruments and probes shall be
capable of being used without difficulty in the temperature range of – 10 to + 50 °C.S creen
High linearity shall be measured and recorded. U.T apparatus shall be adjusted for seep range
and calibrated prior to inspection.
Identification of Weld Defects through Ultra-sonic Testing.
Cracks in weld zones, Lack of fusion in welded joints, Lack of penetration, Pin
holes, porosity, slag, under cuts, blow holes, Root crack, surface crack etc.,
Calibration of Ultra-Sonic Testing
UT Mandatory Calibration is Known as Time Base Calibration, The Process
developed to establish a correspondence between the time spend by the wave to GO
and COME from a known reflector and the distance travelled.
Reference to Standard Specifications and Tolerance Limits.
1. As per ASME 2010 Section VIII-Division -1 of Clause 12.3
Acceptance - Rejection standards

93
 Imperfections which produce a response greater than 20% of the reference
level shall be investigated.
2. As per IS 4260:2004, Reaffirmed 2021.

Dos & Do Not’s @nv

S.
S. No Dos Do Not’s
No
1. Check for the device is having the 1. Do not allow if the required
required frequency. frequency is not available.
2. Check for the technique and use for 2. Do not deviate from the
the appropriate material. specifications
3. Check that ultrasonic instruments and
probes shall be capable of being used
without difficulty in the temperature
range of – 10 to + 50°C.
4. Check that screen height linearity
shall be measured and recorded in
accordance with IS 12666.
5. Check for ultrasonic apparatus shall
be adjusted for sweep range and
calibrated prior to inspection as
described in IS 12666
6. Check the temperature difference
between the examination and the
calibration block surfaces shall be
within 14°C
7. Check for nominal frequency shall be
in the range of 2 to 5 MHz.
8. Name of the operator & ensure the
certificate of operator & validity
period.

1.9.11 Radio-graphic testing

Radiography is an imaging technique that uses electromagnetic radiation other than
visible light, especially X- rays to view the internal structure of a non- uniformly composed
and opaque object (i.e. a non-transparent object of varying density and composition).

To create the image, a heterogeneous beam of X-rays is produced by an X- ray

generator and is projected toward the object. A certain amount of X-ray is absorbed by the
object, which is dependent on the particular density and composition of that object. The X-

94
rays that pass through the object are captured behind the object by a detector (either
photographic film or a digital detector). The detector can then provide a superimposed 2D
representation of all the object's internal structures.

The radiation used in radiography testing is a higher energy (shorter wavelength)

version of the electromagnetic waves that we see as visible light. The radiation can come
from an X-ray generator or a radioactive source.

RADIOGRAPHIC TECHNIQUES:
Technique A -This technique is particularly intended for general application for radiographic
examination. Most applications are covered by the ‘use of this technique’.

Technique B - This technique is intended for more important and critical applications, where
Technique A may not have enough sensitivity to reveal all the defects desired to be detected.
In this technique only fine-grained films or ultra-fine-grained films and lead screens shall be
used. This technique generally requires longer exposure time.

WELD SURFACE PREPARATION:

To simplify interpretation of radiographs, it is advisable to remove surface

irregularities before radiographic examination. In general surface preparation is not, necessary
for radiography, but, where surface irregularities might cause difficulty in detecting internal
defects, the surface may be conditioned by any suitable process.

IMAGE QUALITY INDICATORS (IQI):

Image quality indicator sensitivity is a means by which the quality of radiographic

techniques used may be compared and is not a measure of Saw sensitivity as the latter is a
complex function of the geometry, absorption and location of the flaw.

IDENTIFICATION OF RADIOGRAPHS:
Each section of weld radio graphed shall have suitable symbols affixed to it to identify
a) The job or work piece,
b) The joint,
c) The section of the joint,
d) Manufacturer’s name or trade-mark,
e) Date.

MARKING:

95
 Permanent marking for the work piece shall be used to provide reference points for
accurate relocation of the position of each radiograph.

TECHNIQUES FOR MAKING RADIOGRAPHS:

Films and Screens

Cassettes
Alignment of Beam
Interception of Undesirable and Scattered Radiation
Source-to-Film Distance/Focus-to-Film Distance
Size of Area Examined
Density of Radiograph
X-ray Tube Voltage and Type of Gamma-Ray Sources
Processing
Viewing
RECORD OF TECHNICAL DATA: @nvv

Each radiograph or set of radiographs Information shall be available on the radiographic

technique used. In particular the following shall be recorded:
 Type of X-ray equipment, tube voltage and current or type of radioactive source
together with its strength and size;
 Time of ‘exposure, type of film and screen, and focus-to-film distance/source-to-film
distance;
 System of marking used; and 4 position of IQI, whether source side or 5lm side.

Dos & Do Not’s

S. No Dos S. Do Not’s @nv

No
1. Check for the Sensitivity for adopting 1. Do not adopt if the sensitivity
Technique- “A” or Technique- “B” deflects.
2. Check that in technique-B only fine- 2. Do not allow if fine-grained films
grained films or ultra-fine-grained films or ultra-fine-grained films and
and lead screens are used. lead screens are not used.
3. Check that technique-B is exposed for 3. Do not deviate from the
long duration time. specifications

96
 4. Precautions are taken to protect the
radiographer when X-ray equipment or
radioactive sources are in use.
5. Check that the position of the weld can
be identified on the radiograph.
6. Ensure unequivocal identification of the
section on radiography.
7. Check in separate radiographs of the
joint should overlap at least 10 mm to
ensure that no portion of the joint
remain unexamined.
8. Name of the operator & ensure the
certificate of operator & validity period.

Reference to Standard Specifications and Tolerance Limits.

1. Is Code 1182-1983 (Reaffirmed 2000 recommended- practice for radio-graphic
examination of fusion welded butt joints in steel plates).
2. IS 2595-2008, IS 4853-1982, IS 4260:2001.
3. IS 3657-1978.
1.9.13 Hydro Testing of bare pipe.
Hydro-static Testing means the use of water for pressure testing a pipeline to determine
its integrity
Pressure tests are performed to ensure the safety, reliability, and leak tightness of pressure
systems. A pressure test is required for a new pressure system before use or an existing
pressure system after repair or alteration.
There are two methods for pressure tests
1. Hydrostatic: Each steel cylinder shall be subjected to Hydrostatic test, before
concreting as per IS Code 1916: 1989 is performed by using water as the test medium.
2. Pneumatic: A Pneumatic test uses air, nitrogen, or any non-flammable and non- toxic
gas. Pneumatic tests are potentially more dangerous than hydrostatic because of the
higher level of potential energy. Pneumatic tests may be performed only when at least
one of the following conditions exists:
1. When pressure systems are so designed that they cannot be filled with water.
2. When pressure systems are to be used in services where traces of the testing

97
 medium cannot be tolerated.

HYDROSTATIC TEST PROCEDURE:

1. Ensures the pressure gauges used have current calibration stickers.

2. Remove pressure relief valves or non-reclosing relief device from the vessel or test
boundary where the test pressure will exceed the set pressure of the valve.
3. Holds down each valve by means of an appropriate test clamp and pressurizes both
sides of non-reclosing relief devices.
4. Installs temporary, higher-rated devices where practical Installs the calibrated test
gauge so it is visible at all times.
5. Ensures the skillet blanks or test plugs or clamps are appropriate for use and are free
of obvious defects.
6. Fills and vents system as necessary to remove as much air as practical.
7. Ensures that water used for the test is at not less than ambient temperature, but in no
case less than 70°F.
8. Pressurizes the system, raising the pressure in the system gradually until the designated
test pressure is achieved.
9. Maintains this test pressure for 10 minutes before inspection. Then, if test is above
maximum allowable working pressure (MAWP), reduces to MAWP while making a
full thorough inspection for leaks.
10. Ensures the metal temperature at the time of the hydrostatic test does not exceed 120°F.
11. If there is evidence of structural distortion, either rejects the system or repairs as
advised by the inspector.
12. If there is leakage in the system, ensure for repairs or rejects the system.
13. When the test is completed, vents the test pressure to atmosphere and returns relief
devices to normal configuration.
14. Maintain a pressure test record.
Each section of the Steel Pipe line (including bends fabricated for field erection) Shall be
tested under hydraulic Pressure equal to 1.5 times design pressure for field test and Pressure
equal to 2 times design pressure for yard respectively however pressure for hydrostatic tests,
shall not exceed (i.e. Pressure computed by the following formula straight pipes and bends:

P= (Yp * T) / R
P = Test Pressure in N/mm2.

98
 Yp = Yield Point Stress of Steel used in the Particular
Coarse under test in N/mm2
T= Actual Minimum Wall Thickness of Pipe in “mm” in
the Pipe Length tested.
R= Internal Radius of Pipe in “mm”
Each pipe shall be completely filled with water and Pressure shall be slowly and
uniformly increased until the required test pressure is reached. The test pressure shall be
applied and released THREE TIMES successively and after each application shall be held
steady, for a time stated by the Engineer in charge or till such time until all welded joint and
plate can be examined for defects, leaks etc. Any defects in welds or plates disclosed by the
hydrostatic test shall be repaired by the Contractor to the satisfaction of the Engineer-in-
Charge. All repaired sections shall be again tested for Hydrostatically.

Reference to Standard Specifications and Tolerance Limits

1. IS 3589:2001, IS 5822:1994

1.9.14 REINFORCEMENT FOR THE BARE PIPE

After ensuring the weld and pipe stability, exterior and interior protection work are to
be carried out.
1) Guniting
2) Sand Blasting
3) Epoxy Coating
1) Guniting
Cage reinforcement of Guniting shall be minimum as per IS 432 (Part-I) or IS
432 (Part-II ) Codal provisions.
 Compressive strength of concrete used for coating i.e, Guniting shall be 25N/mm2 at
28 days
 The Elco meter is used for verifying the epoxy coating thickness
 One Field joint out of 10 joints is to be tested.
 All dents more than 2% of outside diameter shall be removed
 Over the ground saddle support and anchorage has to be provided.
 Minimum reinforcement in the guniting shall be 3% of the quantity of steel cylinder
of minimum plate thickness as per IS 1916.

2) Sand Blasting

99
 It is the process to clean the surface to be Epoxied by applying forced fine aggregate.
A compressor will be used to develop the pressure 4 to 6 kg/cm2.A hopper will be filled by
sand and to be connected with gun and hose nozzle assembly. A skilled operator & gun man
have to use this process. The fine aggregates (sand) will be loaded in a special hopper and
keep in closed condition. A hose from compressor can carry 6kg/cm2 pressure of air will be
connected at the bottom of hopper. A gun and hose assembly also connected in exit of hopper.
Which will be sufficient length, so that it can reach where the area will be sand blasted. The
compressed air having 4 to 6 kg/cm2 pressure will carry the sand particle and forcedly apply
the surface so that the rust foreign particle will be removed from the surface to be Epoxied.
The gun will be handled safely and apply over the surface uniformly. So that the rust and all
dusts are removes by this process. The humidity will be checked and the sand blasted will be
done in sunny whether probably. After sand blasting the surface of the pipe will be cleaned
by pure air i.e without sand so that the dust everything will be removed properly.

Reference to Standard Specifications and Tolerance Limits

The minimum roughness of the sandblasted surface should be 2 microns, which should
be measured by a roughness tester.

3) Epoxy Coating
The Epoxy will be over the surface of pipe both inside and outside to avoid corrosion
as well as erosion of bare pipes. It will prevent rust formation from atmospheric
contamination. The Epoxy will be applied in dry season the humidity will be checked during
Epoxy. The method used for Epoxy is spray method. In this method a compressor, hose and
Nozzle will be used to apply the Epoxy. The pressure will be 1.0 to 2.0 kg may be used. The
spray may applied uniformly and the thickness of the Epoxy shall be at least 406 Microns. In
this method we have to do the Epoxy at inside first and outside next. The uniform deposition
will be achieved by skill of operator and quality of Epoxy. After dry of every coat the thickness
will be checked by ELCO meter.

Reference to Standard Specifications and Tolerance Limits

1. As per Relevant Is Codes & Agreement Conditions

Later, we will transport these pipes to a site and lay them either above ground or
underground for the water supply.

100
1.9.15 PIPE LAYING
The following are the steps to be followed while laying a pipe line as per IS 5822-1994
1. Clearing the Site
2. Formation
3. Pipe Handling and Inspection
4. Welding
5. Blank Flanges

CLEARING THE SITE

Preliminary work required to be done before pipe laying is started, includes pegging
out, clearing and disposal of all shrub, grass, large and small hushes, trees, hedges, fences,
gates, portions of old masonry and debris from the route.
All other serviceable materials, such as wood work, bricks and masonry, recovered
during the operation of clearing the site shall be separately stacked and disposed off, as
directed by the Engineer-in-Charge.

FORMATION

Before pipeline is laid, proper formation shall be prepared. For buried pipeline,
suitable trenches should be excavated, pipeline above ground may be laid in cutting or on
embankments or be supported by pillars as the cast may be.
a) Excavation and Preparation of Trenches for Laying underground
Pipeline
b) Preparation of Formation for Pipeline Above Ground
a) Excavation and Preparation of Trenches for Laying underground Pipeline.
The trench shall be so dug that the pipe may be laid to the required alignment and at
required depth. When the pipeline is under a roadway, a minimum cover of 1.0 m is
recommended, but it may be modified to suit local condition's by taking necessary precautions.
The trench shall be shored, wherever necessary, and kept dry so that the workman may work
therein safely, and efficiently.
Trenching:
Trenching includes all excavation which is carried out by hand or by machine.
The width of the trench shall kept to minimum consistent with the working space
required. At the bottom between the faces, it shall be such as to provide not less than

101
200 mm clearance on either side of the pipe. Each case should, however, he considered
on its merits, having regard to the safety of the trench, the method of laying and
jointing the pipe and the need to avoid damage to pipe coating. The bottom of the
trench shall be properly trimmed to permit even bedding of the pipeline. For pipes
larger than 1200 mm diameter in earth and murum the curvature of the bottom of the
trench should match the curvature of the pipe as far as possible, subtending an angle
of about 120* at the centre of the pipe, as shown in Fig. 1 A. Where rock or boulders
are encountered, the trench shall be trimmed to a depth of at least 100 mm below the
level at which the bottom of the barrel of the pipe is to be laid and filled to a like depth
with lean cement concrete or non-compressible material like sand of adequate depth
to give the curved seating, as shown in Fig. 1B and Fig. 1C.

Pits for Joints:

When welding is to be carried out with the pipe in the trench, additional
excavation of not more than 600 mm in depth and 900 mm in length should be
provided all-round the pipe at the position of the joints for facilities of welding.

Special Formation in Poor Soil:

Where the bottom of the trench at sub-grade is found to consist of material
which is unstable to such a degree that, in the opinion of the authority, it cannot be
removed and replaced with an approved material thoroughly compacted in place to
support the pipe properly, a suitable foundation for the pipe, consisting of piling,

102
 timbers or other materials, in accordance with plans prepared by the authority, shall
be constructed.
Rock Excavation:
The term ‘rock: ‘, wherever used in this standard, shall have the same
meaning as given in terminology in IS 1200 (Part 1) :1992.
Blasting:
Blasting for excavation shall be permitted only after securing the approval of
the authority and only when proper precautions are taken for the protection of persons
or property. The hours of blasting shall be fixed by the authority. The procedure of
blasting shall conform to the requirements of local controlling authority (IS 4081:
1986).
Braced and Sheeted Trenches:
Open-cut trenches shall be sheeted and braced as required by any governing
state laws and municipal regulations and as may be necessary to protect life, property
or the work. When close sheeting is required, it shall be so driven as to prevent adjacent
soil from entering the trench either below or through such sheeting.
b) Preparation of Formation for Pipeline Above Ground
Formation should be prepared by cutting high grounds and filling in low areas. Care
shall be taken while fixing the alignment and gradient of the pipeline, to balance the cutting
and filling quantities, as far as possible, with minimum of lead. Care should also be taken to
ensure that the pipe rests fully either on cutting or on bank.
Cutting High Grounds
Excavation for the formation in cutting should be done in such a manner as to
obtain sufficient width at the bottom to accommodate the pipeline, its supports, a
service passage and side drains. The sides of the cutting should generally have the
following slopes:
a) Earth MURUM and boulders 1:l
b) Hard MURUM and soft frocks l/2 : 1
c) Hard rock l/4 :l

103
 All excavated material shall be the property of the authority and shall be stacked or
disposed off as directed under 4.2 above. Typical sections in cuttings are shown in Fig. 2 &

Width of embankment
The width of the embankment at top shall be such as to accommodate the
pipeline and the service passage. Typical section of the bank is shown in Fig. 4.

Material for embankment

Materials used for embankment shall be such that it does not ham the pipeline.
It shall not swell when moisture laden or shrink and crack when dry and shall have
self-draining properties. Mud, clay, slush and decaying vegetable matter shall not be
used. The material shall also be free from cinders, ashes, refuse, rubbish, organic
material, frozen material or material which in the opinion of the authority unsuitable
or deleterious. All lumps and clods shall be broken to allow uniform subsidence of the
earth work throughout the embankment.

Stability of embankment

Embankment shall rest on good foundation which shall be capable of taking

load of the earth fill, the pipeline, service road, etc. When embankment is laid on soft
ground, such as marshy clay or marine clay, such soft foundation shall be stabilized
by providing sand piles or rubble piles. In the alternative, RCC or wooden piles should
be driven to transfer load to harder substrata.

104
PIPE HANDLING AND INSPECTION

It is presumed that the pipes, specials, expansion joints and appurtenances are available
in the stockyard of the authority.
Preliminary Work Before Pipe Laying
i. Bench Marks
ii. Transporting and Stacking of Pipes
iii. Pipe Inspection

WEIDING

The welding of pipes in the field should comply with IS 816: 1969. Electrodes used
for welding should comply with IS 814: 1991.

Testing of Welded Joints

The welded joints shall be tested in accordance with procedure laid down in IS
3600 (Part 1): 1985. One test specimen taken from at least one field joint out of any
10 shall be subjected to test. If the results of the tensile test do not conform to the
requirements specified, retests of two additional Specimen from the same section shall
be made, each of which shall conform to the required specifications. In Case of failure
of one or two, extensive gouging (scooping out) and repairing shall be carried out as
directed by the authority. If internal pressures exceed 1.5 N/mm2, special attention
should be given to the assembly of the pipe and first run of weld. Non-destructive
testing of the completed weld may be carried out on pipelines by radio graphic (see IS
4853: 1982) or ultrasonic method (IS 4260: 2004) as agreed upon between the user
and the manufacturer.
Welding of Closure Gaps
Final welding of closure gaps should be carried out within; I temperature range
of average air temperature +/- 8̊ C. For buried pipelines final welding may best be done
after intermediate pipes have been back filled.
BLANK FLANGES
Blank flanges shall be used at all ends left unattended at the. temporary closure of
work. Blank flanges may also be necessary for commissioning a section of the pipeline or for
testing the pipeline laid. For temporary closures, non-pressure blank flanges consisting of mild
steel plates tack-welded at the pipe ends may be used. For pipes subjected to pressures, the

105
blank flanges should be suitably designed. To prevent the floating of pipes, care should be
taken to see that empty pipes with ends blank flanged should not be left in uncovered
1.9.16 PIPE LAYING PROCEDURE
Before the pipe is lowered, the trench shall be carefully examined to determine that an
even bedding is provided for the pipe line and that the pipe may be lowered into it without
damaging the coating.
Lowering and Assembling of Pipes and Specials
The procedure for lowering varies with the method adopted for coating the pipeline.
Where the coating is to be done in the trench, the pipe may be lowered in the trench on
supports sufficiently high so as to facilitate out-coating. The pipe should be lowered
progressively with the help of shear legs or cranes using wide belts or slings. In case of coated
pipes, extra care shall be taken to preserve the coating while lowering. Slings may be
removed progressively without the necessity of digging under the pipe. Where the trench is
sheeted, the pipes shall be lowered into the trench by removing at a time, one or two struts
only, care being taken to see that no part of the shoring is disturbed or damaged. If necessary,
additional struts may be fixed during lowering. After the pipe is lowered, it shall be
laid in correct line and level by use of levelling instruments, sight rails, theodolites, etc. Care
shall be taken to see that -the longitudinal joints of the consecutive pipes are staggered by at
least 30” and should be kept in upper third of the pipeline, if there are two longitudinal joints
they should be on the sides. While assembling, the pipe faces shall be brought close enough
to leave a uniform gap not exceeding 3 mm. The spiders from inside and tightening rings from
outside or other suitable equipment should be used to keep the two faces in shape and position
till at least one run of welding is carried out.
The pipe faces shall first be tack-welded alternately at one or more (diametrically
opposite pairs of points. After completing tack-welding, full welding shall be carried
out in suitable runs following a sequence of welding portions of segments diametrically
opposite.
Back filling
Back filling should closely follow the welding of joints of the pipe so that the
protective coating should not be subsequently damaged. Material harmful to the pipe
line shall not be used for back filling. Refilling shall be done in layers not exceeding 300 mm.
Each layer shall be consolidated-by watering and ramming, care being taken to prevent

106
damage to the pipeline. The filling on the two sides of the pipeline should be carried out
simultaneously.
The spiders provided during assembly and welding shall be retained until the trench is
refilled and consolidated. Where timbers are placed under the pipeline to aid alignment, these
shall be removed before backfilling. For further precautions and use of material in backfilling,
reference should be made to IS 3114: 1994.
Laying of Pipes Above Ground
The pipeline may be allowed to rest on ground, if the soil is non aggressive.
The ground should, however, be dressed to match the curvature of the pipe shell for an arch
length subtending an angle of 120° at the centre of pipes. Alternatively, the pipeline should
be laid either on saddle or roller and rocker supports as specified by the authority. Figures 5
and 6 show supports generally adopted in steel pipelines.

1.9.17 TESTING OF PIPELINE

Before putting it into commission. the welded pipeline shall be test for both strength
and leakage.
Each valved section of the pipe shall be slowly filled with clean water and all air shall
be expelled from the pipeline through hydrants, air valves and blow-offs fixed on the pipeline.
Before starting the pressure test, the expansion joints should be tightened.
Pressure Test
The field test pressure to be imposed should be not be less than the greatest of the
following:
1. 1 times the maximum sustained operating pressure
2. 1 times the maximum pipeline static pressure,
3. Sum of the maximum static pressure and surge pressure subject to the test pressure.
where the field test pressure is less than two-thirds the test pressure, the period of test should
be at least 24 hours. The test pressure shall be gradually raised at the rate 0.1 N/mm2 per
minute. if the test pressure measurement arc not made at the lowest point of the section, an

107
allowance should be made for the static head between the lowest point and the point of
measurement to ensure that the maximum pressure is not exceeded at the lowest point. If a
drop in pressure occurs, the quantity of water added in order to re-establish the test pressure
should be carefully measured. This should not exceed 0.1 litre per mm of pipe dia per km of
pipeline per day for each 30 m head of pressure applied.
Where the pipeline is tested in sections, two or more welded joints at each gap may
not get tested under Pressure. Special care should be taken in making these welds and these
joints should be kept under observation during the commissioning of the system.
Each valved section of pipe shall be filled with water slowly and the specified test
pressure, based on the elevation lowest point of the linear section under lest and corrected to
the elevation on the test gauge, shall be applied by means of a pump connected to the pipe in
a manner satisfactory to the authority.
Under the test pressure no leak or sweating shall be visible in all suction of pipes,
fillings, valves, hydrants and welded joints. Any defective pipes, fittings, Valves or hydrants
discovered in consequence of this pressure test shall be removed and replaced by sound
material and the test shall be repeated until satisfactory to the Authority.

1.9.18 COATINGS
Buried Pipes
Buried steel pipe lines are liable to external corrosion and should be protected
by the use of suitable coatings and shall be in accordance with IS 10221: 1982.
Above Ground Pipelines
Pipe lines laid above ground are liable to, atmospheric corrosion and should be
adequately protected.
Internal Coating or Lining
Where water to be conveyed is aggressive in nature, the pipeline should be
provided with an internal coating or lining, such linings arc usually of bitumen, coal
tar, epoxy resin, concrete or cement motor or plastic lining. Care should be taken to-
see that the material used for coating is non-toxic. The lining may be applied to the
pipe before or after laying. In the former case, it should be made continuous at the
joints after laying. Methods of applying internal lining vary according to the size of
the pipe depending upon the working space inside the pipe. In case of large diameter
pipelines, cement mortar lining preferably be carried out after the pipeline is laid in

108
 position and the backfill in the trenches is properly consolidated. This will prevent the
lining from being damaged due lo deformation of pipeline, due to self weight and also
due to handling of pipes during laying operation.
Dry film Thickness
Both for internal and external-painting, the thickness of the dry paint film is
very important from the point of view of determining the protective life. The minimum
dry film thickness of the paint system should be specified and measurements to that
effect be made by using instruments like Elco-meter or similar other reliable
measuring devices.

1.9.18 CENTRIFUGALLY CAST (SPUN) DUCTILE IRON PRESSURE PIPES FOR

WATER, GAS AND SEWAGE IS 8329 -2000 (Reaffirmed 2005)

Ductile Iron - Type of iron used for pipes, in which graphite is present primarily in
spheroidal or nodular form.

1.9.19 CLASSIFICATION

Pipes have been classified as K7, K8, K9, KIO, K12, depending on service conditions
and manufacturing process.

The class designation shall comprise of:

a) a prefix K.

b) a whole number used for thickness class designation, [this is the selected
coefficient inserted into the equation (1) depending on the service conditions].

The wall thickness of pipe ‘e’ in mm shall be calculated as a function of the nominal diameter
by the following equation with minimum of 5 mm for K=7, 6mm for K=8 and 7 mm or K=12.

e = K (0.5 + 0.001 DN)

where

e = wall thickness in mm,

DN = the nominal diameter, and

K = the whole number coefficient.

109
The value of K will depend on the following service conditions:

For screwed or welded eon flange pipes the minimum classes as per working pressure
criteria are given below:

1.9.20 MECHANICAL TESTS

Mechanical tests shall be carried out during manufacture. One test shall be conducted
for every batch of production.
1. Tensile Test:
The thickness of the sample and the diameter of the test bar shall be as given below

2. Brinell Hardness Test

When tested in accordance with IS 1500, the Brinell hardness shall
not exceed 230 HB on the external un-machined surface.
3. Hydro-static Test
All pipes shall be tested hydrostatically at a pressure specified in Table 1. To
perform the test, pressure shall be applied internally and shall be steadily
maintained for a period of 10 s. The pipes shall withstand the pressure test and

110
 shall not show any sign of leakage, sweating or other defects of any kind.

SIZES
The standard nominal diameters DN, of pipes and flanges followed in this standard
are as follows:
80, 100, 125, 150,200,250,300,350,400,450, 500, 600, 700, 750, 800, 900, 1000, 1
100, 1200, 1400, 1600, 1800 and 2000 mm.
DIMENSIONS
I. Length
II. Internal Diameter
III. Wall Thickness
1.9.21 TOLERANCES
External Diameter

The values of the external diameter (DE) of the spigot end of socket and
spigot pipes and when measured circumferential using a diameter tape shall confirm
to the requirements specified in 12. The positive tolerance is + 1 mm and applies to
all thickness classes of pipes. The negative tolerance of the external diameter
depends on the design of each type of joint and maximum negative tolerance is
specified in this standard.

Tolerance on Ovality
Pipes shall be as far as possible circular internally and externally. The tolerance
for out of roundness of the socket and spigot ends in the jointing zone for push-on-
joint is given in Table 8 and for mechanical joint is given in Table 9.

111
 Tolerance on Length

1.9.21 COATING
Pipes shall be normally delivered internally and externally coated.
External Protection
By agreement between manufacturer and the purchaser, any one of the
following protection may be applied depending upon the external condition of use:
1. Metallic zinc with finishing layer
2. Zinc rich paint with finishing layer
3. Bituminous paint
4. External Sleeving

112
113
 PART-II

IN GENERAL

114
 2.1 LIST OF REGISTERS TO BE MAINTAINED AT THE SITE BY
CONSTRUCTION STAFF

S. No. Registers Remarks

SECTION- I (GENERAL)

1. Site Order Register

2. Placement Register

3. Register of Registers

4. Register of Laboratory Inventory

5. Register of Approved Drawings

SECTION- II (SURVEYING)

1. Register of Bench Marks

2. Register of Control Points

SECTION- III (EARTHWORK)

1. Register for Soil results

2. Register for Compaction (PD)

3. Register for Permeability

4. Register of SBC values and their properties

SECTION- IV (REINFORCEMENT)

1. Register of Bar Bending Schedule

2. Register of Steel Results

SECTION- V (INPUT MATERIAL)

1. Register of Coarse Aggregate (Sieve Analysis, Flakiness and

Elongation index, Impact Value etc.,)

2. Register of Fine Aggregate (Sieve Analysis, Silt Content etc.,)

3. Register of Cement (Fineness, Consistency, Initial & Final

setting time, Compressive Strength of Cement etc.,)

SECTION- VI (CONCRETE)

1. Register for Concrete Slump & Temperature

115
 2. Register of Concrete Cube Testing

3. Register of Concrete Core Testing

4. Register of Acceptance Criteria of Cube Test

5. Register of Acceptance Criteria of Core Test

6. Register of Concrete load at Batching Plant

SECTION- VII (PRESSURE MAINS)

1 Register of Supply of Plates

2 Register of Marking & Cutting

3 Register of Fit-up

4 Register of SAW

5 Register of Ultra Sonic Testing-Fabrication Yard

6 Register of Radiography Testing-Fabrication Yard

7 Register of Hydro Testing-Fabrication Yard

8 Register of Sand Blasting

9 Register of Epoxy

10 Register of Ultra Sonic Testing-Field

11 Register of Hydro Testing-Field

12 Register of supply of Electrical parts equipment

13 Register of supply of mechanical parts equipment

14 Register of spare parts Equipment

*Note*

The Engineer-in-charge has to issue required registers, based on the requirement of the

work.

116
 2.2 O. K. CARDS

2.2.1 GENERAL

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

stages and are liable to be referred/perused at a later stage also, particularly during the Internal
Quality Audit of works, the O. K. Cards shall be maintained in triplicate in three colours. The
green coloured card shall form a part of the record of Q.C. wing, the pink coloured card remains
in the custody of construction wing and white coloured card remains in the custody of agency.
Senior officers shall also check the O. K. Cards during their field inspections to ensure that
those are being maintained and properly/genuinely filled.

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

achieving specified workmanship and quality level of output. Each work is sub-divided into
various construction activities in proper sequence/order of construction. Such activities are
listed in chronological order on the O. K. Cards.

For various stages of construction activities where laboratory tests are checks with
reference to drawing and specification are required from quality control unit. O. K. Card
System shall be followed. The O. K. Cards should be made available on the site in a regular
manner.

The O. K. Card consists of 3 columns. Besides, the location and type of work, the first
column is to be filled by the agency (Contractor), by preparing each feature and making it ready
for inspection by the Construction Engineer, who Okays through his signature and then puts
up to the Q.C Engineer.

The quality control staff at actual work site shall check the requirement or shall perform
necessary tests, if anything found defective in the test, it is to be informed to the construction
staff for rectification.

Subsequently, O. K. Card should refer to the defects removed, if pointed out previously
in O. K. Cards and counter reference to the previous Check and should be signed if Okay-ed.

It must be borne in mind that work cannot be held up unduly for disposal of O. K. Card.
Random checks by Superior officers should be recorded on O. K. Cards at site.

After processing through various levels and entering observations one copy of the
O. K. Card (pink colour Card) shall be retained with the Assistant Executive Engineer
(Construction) for record and the other copy (green colour) shall be forwarded to the Executive
Engineer Quality Control for record.

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

grouting and tunneling etc., have been enclosed below.

NOTE: O. K. Card is not static, it is dynamic and can change the requirements according to the
site conditions, agreement conditions and as per the approved bid documents. The concern
formats has enclosed in ANNEXURE-VII.

117
2.3 DETAILS OF TESTS TO BE CONDUCTED BEFORE, DURING &
AFTER THE WORK - LIST OF EQUIPMENTS
Equipm
S. Compon Descripti Reference
ent Acceptanc Remark
N ent of on of Purpose to Test
Require e Criteria s
o. Testing Test Procedure
ment
ENGINEERING MATERIALS
IS
Sieves
Methods 80mm,
of Test 60mm,
for 40mm, IS : 2386
Aggregat 20mm, ( Part 1 ) - Before
es for 16.5mm, To know
As per IS: 1963 and
Concrete 10mm, the 383-2016 (Reaffirmed During
5.6mm, gradation
Year : 2021 the Work
Particle 4.75mm, )
Size and Lid &
Shape Receiver
and
Balance
@nvv

To assess
Balance,
Specific the
Oven, A IS : 2386
Gravity suitability
wire ( Part 3 ) Before
and of
basket, As per - 1963 and
Coarse Water aggregate design mix
Water (Reaffirmed During
1 Aggregat Absorpti used in the
tight Year : 2021 the Work
e on and data for
Containe )
Bulking mix
r
design
To assess
the
IS : 2386
suitability
Balance, ( Part 3 ) - Before
of
Bulk Oven, 1963 and
aggregate __
Density Glass (Reaffirmed During
used in the
Vessel Year : 2021 the Work
data for
)
mix
design
IS
Sieves IS : 2386
Elongatio 63 mm, To assess ( Part 1 ) - Before
n& 50 mm, the quality As per 1963 and
Flakiness 40mm, of design mix (Reaffirmed During
Index 31.5mm, materials Year : 2021 the Work
25mm, )
20mm,

118
 16mm,
12.5mm,
10mm
and
6.3mm,
Length
Guage
Reactivit
y
Containe
r
Weighin
g Scales,
Alkali Weights,
IS 2386 :
Aggregat Sieves,
Part 7 :
e Glass To assess Before
1963 (Rea
reactivity Graduate the quality and
__ ffirmed
test s, of During
Year : 2021
(Reaction Specime materials the Work
)
Chamber n mould,
s) Mixing
Bowl,
Tamper,
trowel
and
Containe
r
IS 2386 :
Oven, Loss with Part 5 :
Na2So4< Before
Sieves 1963 (Rea
Soundnes 12% and
and Loss with
ffirmed
s During
Containe MgSo4< Year : 2021
the Work
rs 18% )

An
Impact
Testing
Machine
To assess
,
the quality
Cylindri
of
cal IS 2386 :
materials Wearing
Metal surfaces < Part 4 : Before
Aggregat
measure, 30% 1963 (Rea and
e Impact Other
Tamping ffirmed During
Value concrete - <
Rod, S Year : 2021 the Work
Sieves- 45%
12.5
mm,10m
m and
2.36
mm,
Balance

119
 Los
Angeles
Abrasion Wearing IS 2386 :
Testing surfaces - < Part 4 :
Aggregat 30% Before
Machine 1963 (Rea
e Other and
IS 2386 ffirmed
Abrasion concrete - < During
(Part- 50% Year : 2021 the Work
value
IV)-
1963,
Sieves,
Balance
15 Cm
Dia open
ended
steel
cylinder
with
plunger
and base
plate, IS 2386 :
Aggregat tamping To assess Part 4 : Before
e rod, IS the quality 1963 (Rea and
__
Crushing Sieves- of ffirmed During
Value 12.5 materials Year : 2021 the Work
mm,10m
m and
2.36
mm,
balance ,
Compres
sion
Testing
Machine
IS 2386 :
Sodium To assess Part 2 : Before
Organic
Hydroxi the quality 1963 (Rea and
Impuritie __
de, Glass of ffirmed During
s
Jars materials Year : 2021 the Work

IS
Sieves,
Balance,
anvil and To know IS 2386 :
hammer the extent Part 8 :
Petrograp Before
suitable of 1963 (Rea
hy and
for deleteriou __ ffirmed
examinati During
breaking s materials Year : 2021
on the Work
pebbles, and Silt )
Hand content.
lens,
stereosc
opic

120
 microsco
pe and
auxiliary
equipme
nt for
adequate
petrogra
phic
examinat
ion and
identific
ation of
rocks
and
minerals
@nvv

containe IS : 2386
r, ( Part 1 ) - Before
Moisture balance 1963 and
__
Content and (Reaffirmed During
frying Year : 2021 the Work
pan )
Balance,
Oven, A IS : 2386
wire ( Part 3 ) Before
Absorpti basket, - 1963 and
__
on Value Water (Reaffirmed During
tight Year : 2021 the Work
Containe )
r
Digital
IS 2386 :
Potential length
Part 7 : Before
Reactivit compara
1963 (Rea and
y of tor with __
ffirmed During
Aggregat air tight
Year : 2021 the Work
e lid and
)
rod
IS
Sieves
4.75mm,
1.18mm, As per
2.36mm, To know design mix
600micr the grain Concrete, IS : 2386
Sieve IS:383-
ons, size and ( Part 1 ) - Before
Fine Analysis 2016
300micr fineness 1963 and
2 Aggregat / Masonry,
ons, modulus IS:2116- (Reaffirmed During
e Fineness
150micr of sand 1965 Year : 2021 the Work
Modulus
ons, 75 and silt Mortar )
microns, content Plaster:IS:1
Lid & 542-1960
Receiver
and
Balance

121
 IS : 2386
Deleterio Deleterious
Sodium To assess ( Part 2 ) - Before
us and constituents
Hydroxi the quality 1963 and
Organic plus silt not
de, Glass of more than 5 (Reaffirmed During
Impuritie
Jars materials percent Year : 2021 the Work
s Test
)
To know
suitability IS : 2386
Measuri of sand ( Part 3 ) - Before
Unit ng Jar and to 1963 and
__
Weight and Steel utilize (Reaffirmed During
Rod data for Year : 2021 the Work
mix )
design
Balance, To know
Cylindri suitability IS : 2386
cal of sand ( Part 3 ) - Before
Metal and to 1963 and
Bulk age __
Measure utilize (Reaffirmed During
and data for Year : 2021 the Work
Tamping mix )
rod @nvv design
Balance,
Specific IS : 2386
Oven,
Gravity To utilize ( Part 3 ) - Before
Glass
and data for As per 1963 and
Vessel design mix
Water mix (Reaffirmed During
and
Absorpti Design Year : 2021 the Work
Pycnom
on )
eter
IS : 2386
Balance,
To utilize ( Part 1 ) - Before
Containe
Moisture data for 1963 and
rs and __
Content mix (Reaffirmed During
frying
Design Year : 2021 the Work
pan
)
Residue
Balance, less than 10
90 percent. IS : 4031
Micron Not less ( Part1 & 2 ) Before
sieve than 225
Fineness - 1988 and
and m2/Kg for
Test To assess OPC, and (Reaffirmed During
Brush
the quality Not less Year : 2021 the Work
Blaine’s
of cement than 300 )
3 Cement Apparat
used in m2/Kg for
us
constructi PPC
Vicat on IS : 4031
Apparat ( Part 4 ) - Before
Normal
us with 1988 and
Consisten __
10mm (Reaffirmed During
cy
dia Year : 2021 the Work
Plunger. )

122
 Vicat
Apparat Initial-Not IS : 4031
Initial us with less than 30 ( Part 5 ) - Before
and Final Initial minutes. 1988 and
setting and Final – Not (Reaffirmed During
time Final more than Year : 2021 the Work
setting 600 minutes )
needles
IS : 4031
Le- Le-Chatlier ( Part 3 ) - Before
Soundnes Chatliers expansion 1988 and
s Test Apparat less than 10 (Reaffirmed During
us mm Year : 2021 the Work
)
IS : 4031
Specific
( Part 11 ) - Before
Gravity
Specific 1988 and
bottle, __
Gravity (Reaffirmed During
Kerosen
Year : 2021 the Work
e
)
2
3 7
8
d d
d
a a
a
y y
y
s s
s
Cube O
Mould P
2 3 4
7.06 Cm, C
3 3 3 IS : 4031
Vibratin 4
N N N ( Part 6 ) - Before
Compres g 3
/ / /
g 1988 and
sive Machine r
m m m
m m m (Reaffirmed During
strength and a 2 2 2 Year : 2021 the Work
Compres d )
sion e
Testing
5 3
Machine 2 5
3 7
7 3
g N
N N
r /
/ /
a m
m m
d m
m 2 m
e 2 2

Prism IS : 4031
Mould ( Part 10 ) - Before
Drying
(50X50 1988 and
Shrinkag
X200), (Reaffirmed During
e
rod of Year : 2021 the Work
205 mm. )
Chemical IS : 4032 –
Analysis 1985

123
 Slump
To Check
Cone
workabilit
with
Temperat y of
Rod, IS 1199 Part During
ure & Concrete/ __
Industria 2: 2018 the work
Slump Water-
l
Cement
Thermo
ratio
meter
Batch
Mixer,
Vibratin
Compres g Table, IS
To assess
sive Cube 456:2000,
28 days
Strength Mould, IS 516 : During
compressi __
of Compres 1959 (Rea the work
ve
Concrete sion ffirmed
strength
Cubes Testing Year : 2018
Machine
,
Balance
Concrete To assess
Core the
Drilling density,
C C Core
Machine segregatio IS 516 : Part After the
Extractio __
with n and 4 : 2018 work
n
4 Concrete various compressi
@nvv

diameter ve
drill bits strength
Permeab To know
ility cell, the IS 3085 :
Water Permeabili 1965 (Rea
Permeabi After the
reservoir ty of __ ffirmed
lity work
, Concrete Year : 2021
Pressure used for
lines Lining
IS:
To know
Rebound 13311(Part
the
Rebound hammer 2):1992 After the
strength of __
hammer Apparat (Reaffirmed work
Concrete
us Year : 2004)
strength
To know
Pulse IS 516
Ultrasoni the
Velocity (Part-5/Sec- After the
c pulse strength of __
Apparat 1) work
velocity Concrete
us
strength
Compact To know
Before
Compacti ion the
IS 1199 Part and
on factor Factor Workabilit __
2: 2018 During
test Apparat y of
the Work
us Concrete

124
 To know Before
IS 1199 :
Air Air the Air and
__ Part 4 : 2018
content meter Content of During
Concrete the Work
To
Diameter Vernier
determine Before
and calipers
the IS and
Weight and __
diameter 1786:2008 During
Determin Weigh
and the Work
ation Balance
weight
To
determine
Tensile Before
Universa the IS 1608:
Strength, and
l Testing Tensile __ Part 1 : 2022
Elongatio During
5 Steel Machine strength &
n the Work
Elongatio
n of steel.
To
determine
steel IS 1599 : Before
Bend and Universa
ductility 2023 and
Re-bend l Testing __
without & IS During
Test Machine
affecting 1786:2008 the Work
the steel
strength
Before
To Know
PH Value As per IS As per IS and
the nature 3025-1983
test 3025-1983 During
of water
the Work
IS 3025 :
Part 22 :
Before
Limits of 1986 (Rea
and
6 Water acidity __ ffirmed
During
test Year : 2019
the Work
)

IS 3025 : Before
Limits of
Part 23 : and
Alkalinit __
2023 During
y test
the Work
Percentag
e of
solids
such as
Chlorides IS 3025 : Before
, Part 15 : and
__
Sulphates 2023 During
,Suspend the Work
ed Matter
,
Oraganic
and

125
 Inorganic
impuritie
s

TUNNELING

a) Access
and haul
roads
where
cross
traffic or __
other
hazardou
s
condition
s exist.
b)
Bridges For
c)Concret Luxo improving IS 4756 :
e placing meter(lu performan 1978 (Rea
LIGHTI d)Underg x) ce and ffirmed During
1
NG round Least quality in Year : 2022 the work
works Count=0 the )
(Working .01 lux working
faces) area @nvv

e)
Junction
f)
Operator’
s cabin of
machines
g)
Maintena
nce shops
and
auxiliary
buildings
I) Purity
requirem
For
ent Multi
improving
a) Carbon Gas Not More
performan
Monoxid Detector than
VENTIL ce and
2 e (PPM) 0.005%
ATION quality in
b) Least Not less During
the
Oxygen Count=0 than 19.5% the work
working
c)Hydrog .1 PPM Not More
area
en than
Sulphide 0.001%

126
 Not More IS 4756 :
than 0.5% 1978 (Rea
at any ffirmed
place Year : 2022
d)Methan inside the )
e tunnel , for
Eg. In a
cavity in
the roof
etc.
e) Carbon Not More
di oxide than 0.5%
f) Not More
Nitrogen than
fumes 0.0005%
As
formaldeh
g)
yde not
Aldehyde
more than
0.0002%
On tunnel
work 4.25
m3 of Air /
min / man
is usually
considered
the
minimum
requireme
nt. In
addition to
this 2.0
II)
m3 of Air /
Volume IS : 4576 During
min shall
of Air - 1968 the work
be
required
supplied
for such
brake
horse
power of
Diesel
locomotive
or other
diesel
engine
used in
tunnel.
Ensure
III) Temperatu
IS : 4576 During
Temperat res of not
- 1968 the work
ure more then
40 º C Dry

127
 and 29 º C
wet at
working
place
It is the
Sound
level
Pressure
below
a) Work Level
which
limit Meter __
very little
value Least
risk to an
Count=0
unprotecte
.1 Db
d ear
Above
which the
danger of
hearing
b)
impairmen
Danger During
t and
Limit the work
deafness
Value
may result
NOISE from an
3 CONTR unprotecte
OL d ear.
Worker
should
c)Danger
wear During
Limit
appropriat the work
Value
e ear
protection.
Personal
d)Danger protective
During
Limit equipment
the work
Value shall be
worn.
No worker
IS 4756 :
e) Danger shall be
1978 (Rea During
Limit allowed to
ffirmed the work
Value enter the
Year : 2022
area.
)
This limit
value will
The total
be
dust if
NCB/M applicable
Respirabl exceeds
RE Dust when the
e dust in 10mg /
DUST Sampler respirable
the work m3, During
4 CONTR Type dust
front ventilation the work
OL 113 A contains
during shall
IS : 4576 5% or less
each shift beadequate
- 1968 silica in
ly
air borne
improved
dust.
Where

128
 dust
contains
more than
5% quartz
or free
silica the
limiting
value shall
be
determine
d by the
following
formula
(5 ÷ % of
respirable
quartz or
free silica
mg/m3) @nvv

To assess IS 2770 :
the bond Part 1 :
Pull Out
strength of 1967 (Rea
Test on
PULL Central the ffirmed
Anchor During
5 OUT Hole embedded __ Year : 2022
bars and the work
TEST Jack rock bolts ),IS code
Rock
and IS:11309-
bolts
anchor 1985
bars
To assess
GRP
Ground Ground the
survey After the
6 Penetrati Penetrati thickness, __ __
equipme work
on Radar on Radar homogene
nt
ity

SHOTCRETING

Slump
To Check
Cone
work
with
Temperat ability of
Rod, During
ure & Concrete/ __
Industria the work
Slump Water- IS 9012 :
During l
Cement 1978
1 Construc Thermo
ratio (Reaffirmed
tion meter
Year : 2021
To Check
),
the air
Air Air (ASTM During
content in __
content meters C1583/C158 the work
fresh
3M)
concrete
Size To assess
Unreinfor
shall not 7 days, 28 During
ced Test __
be less days the work
Panels
than 75 Compressi

129
 cm * 75 ve
cm and strength,
thicknes Density
s shall and
not be Segregatio
less than n of mix
7.5 cm
To assess
Minimu 28 days
m Dia of Compressi
C C Core 7.5 cm ve
After the
Extractio and L/D strength, __
work
n ratio Density
greater and
than 1 Segregatio
n of mix
To assess
the
bonding
between
After Bond
Bond old After the
hardenin Strength __
strength Structural work
g and tester
Surface
2 appropria
and short
tely
crete
cured
Overlay
and aged.
Flexural
propertie
s- for To assess
Fiber RDP test the After the
__
Reinforce System flexural work
d Strength
Shotcreti
ng.
To assess
GRP
Ground the
survey After the
Penetrati thickness, __
equipme work
on Radar homogene
nt
ity

BARRAGES/SPILLWAYS

a. Gro
up Strain
meter-6 IS 14248 :
__
Nos 1995 (Rea
Instrume Measurin group/Bl ffirmed
1
ntation g Device ock Year : 2020
b. No )
Stress
__
strain
meter-6

130
 Nos
/Block

c. Stres
s meters
-6 __
Nos/Blo
ck
d. Joint
meters -
__
8 Nos
/Block
e. Up
lift
pressure
meters - __
8
Nos/Blo
ck
f. Inve
rt Plumb
line -- 1 __
No/Bloc
k
g. Nor These
mal are
Plumb indicativ
__
line- 1 e and
No/Bloc additiona
k l
h. Aut equipme
omatic nt shall
water be
level __ decided
Indicator with the
s- 1 Set approval
/Block of Chief
i. Mul Engineer
ti point /CDO
bore
Extenso __
meter- 1
No/Bloc
k
j. Incl
inometer
__
- 1 Set
/Block
k. Swit
ch cum __
junction

131
boxes - 6
Nos/Blo
ck
l.
Readout
unit - 1 __
No/Bloc
k
m. Cable
point
housing
__
-6
Nos/Blo
ck
n.Autom
atic
__
weather
station
o.
Triaxial
__
Joint
meter
p.
Survey
__
target
points
q.
Tempera
ture
__
meter -8
Nos/Blo
ck
r. Pore
pressure
meter - 8 __
Nos/Blo
ck
s. Strong
Motion
Accelero
__
meter -1
Set
/Block
t.
Automat
ic Data
Acquisiti
on __
Station -
1
No/Bloc
k

132
 Viscome
ter with To find IS 14344 :
Cut off Cup and the 2021
Bentonit
Trench Bob (or) movement IS 12584 : During
2 e (Cut of __
rhelogy Viscome of 1989 the work
trench)
test ter with Bentonite ASTM
Plate and slurry @nvv D7175-15
Cone

EARTH DAM AND CANAL EMBANKMENTS

Electroni
c
weighin
g
balance
500 g
Capacity
,
Counter
scale To know IS 2720 :
Grain balance the Part 4 :
As per
size 20 kg classificati 1985 (Rea
design Before
analysis capacity, ons of soil ffirmed
Year : 2020 &During
for sieves actually
) the work
classifica 4.75 put in the
tion mm, embankm
2.36 ent
mm,
1.18mm,
600micr
1 Soils ons, 300
microns,
150
microns,
75
microns.
Liquid To know IS 2720 :
Workable
Limit the Part 5 :
range for
device, classificati 1985 (Rea
hearting Before
Atterberg Poreceli ons of soil ffirmed
LL PL PI &During
Limit test n dish, actually Year : 2020
35 20 15 the work
Groving put in the )
To To To
tool, embankm
50 30 30
spatula ent
IS 2720 :
To know Part 4 :
Hydrom
Hydrome the 1985 (Rea Before
eter test
ter percentage __ ffirmed &During
apparatu
analysis of silt and Year : 2020 the work
s
clay )

133
 Density
To know IS 2720 :
Bottle of
the Part 3 :
50 ml Before
classificati 1985 (Rea
capacity and
Specific ons of soil ffirmed
Water __ During
Gravity actually Year : 2020 the Work
bath,
put in the )
desicator
embankm
s, glass
ent
road
Minimum
98% of IS 2720 :
Core
To MDD. Part 28&
cutter,
Field determine Main canal 29 :
rammer,
Density the Field and 1985 (Rea During
dolly
and density Branch ffirmed
and all the work.
Moisture and canal and Year : 2020
other
content moisture 95% of )
accessori
content Distributar
es
y & Dowel
banks.
Workable
To range for
determine hearting,
IS-
Permeab permeabili less During
2720(Part
Permeabi ility ty than10-6 the work
17):1986
lity Test Apparat characteris cm/sec. & After
(Reaffirmed
us tics of the Casing the Work
-2021)
fill more than
material 10-4
cm/sec.
IS 2720 :
To know
Shear Part 13 :
the shear Before
Direct box with 1986 (Rea
characteris As per and
Shear all ffirmed
tics of fill design During
Test accessori Year : 2021
material the Work
es )
(in-situ)
IS 2720 :
To know
Shear Part 11 :
the shear Before
Tri-axial box with 1993 (Rea
characteris As per and
Shear all ffirmed
tics of fill design During
Test accessori Year : 2021
material the Work
es )
(in-situ)

134
 consolid
ation
ring and
cell, Dial
S 2720 :
gauge To know
Part 15 :
and the
1965 (Rea
Consolid loading settlement As per During
ffirmed
ation Test device, rate and design the work
Year : 2021
Trimmin its
)
g magnitude
equipme
nt
,balance

To
determine
Cylindri MDD and
IS 2720 :
cal OMC of
Part 7 &8:
Metal the soil Before
Standard 1980 (Rea
Mould, and As per and
Proctor ffirmed
Balance, compare design During
Test Year : 2021
Oven, the results the Work
)
Rammer, with
etc., Laborator
y value

To know IS 2720 :
the Part 2 : Before
Moisture moisture As per 1973 (Rea and
content content of design ffirmed During
the sample Year : 2020 the Work
)
Evaporat
ing dish,
IS 2720 :
shrinkag
To Part 6 : Before
e dish,
Shrinkag determine 1972 (Rea and
measurin __
e Factor shrinkage ffirmed During
g jar,
limited Year : 2021 the Work
mercury
@nvv

)
250g

S 2720 :
ID =( emax
Relative Part 14 : Before
– e)/(emax
Relative Density As per 1983 (Rea and
– emin), design
Density Apparat ffirmed During
e=Grw -1
us Year : 2020 the Work
/ra
)
To know
Swell Swell IS 2720 :
the swell
Pressure Pressure Part 41 : During
pressure __
test of apparatu 1977 (Rea the work
of BC
Black s ffirmed
soils

135
 cotton Year : 2021
soils. )

IS 2720
To know
(Part-40):
the swell
Swell 1977 Before
index of __
Index (Reaffirmed the work
swelling
2021)
soils
Subjected
to σ1and
σ2=σ3=0.
IS 2720:
The U.C
Unconfin Proving Part 10 :
Test is Before
ed ring 1991 (Rea
applicable and
Compres attached __ ffirmed
to During
sive to a load Year : 2020
saturated the Work
strength frame )
case for
which Ø is
0.

In-situ
Tests on
Embank
ment
Field
Density/
Compacti
on
efficienc
y using
nuclear
moisture
density
To know During
gauge Nuclear __ __
compactio the work
(electroni Density
n
cequipme Gauge
efficiency
nt)
compacti
on
efficienc
y by core
cutter
method

136
 1. To
know the
water
tightness
In-situ of
permeabi banking,
During
lity test __ 2. __ __
the work
Japanese Hearting <
method 10 -6 cm
/sec, 3.
Casing>10
-4
cm/sec

FILTER
S
To find %
of the IS 8419 :
Grain
D10, D15, Part 1 : Before
Size
D30, D50, 1977 (Rea and
Analysis __
D60 and ffirmed During
for metal
D85 grain Year : 2021 the Work
and sand
sizes of
materials
Clay To find
lumps out clay Before
and lumps & and
__ __
organic Organic During
impuritie impurities the Work
s level
ROAD WORKS
__ Before
To Know
Gradatio Size of IS 2386 : and
n Aggregate Part-1 During
@nvv
the Work
IS 2720 :
To know Part 5 : Before
Liquid the 1985 (Rea and
Granula __ ffirmed
limit classificati During
1. r Sub- ons of soil Year : 2020 the Work
Base )

IS 2720 :
To know Part 5 : Before
Plasticity the 1985 (Rea and
__ ffirmed
Index classificati During
ons of soil Year : 2020 the Work
)

137
 IS 2720 :
Moisture Part 2 :
To know 1985 (Rea Before
Content
the water ffirmed and
Prior to __
content of Year : 2020 During
Compacti
the soil ) the Work
on

IS 2720 :
Part 8 : Before
To know 1985 (Reaff
Proctor and
the dry __ irmed
test During
density Year : 2020 the Work
)

Before
To know IS 2720 :
and
CBR Test the dry __ Part 16 :
During
density 1985
the Work
IS 2720 :
Part 3 : Before
Water To Know
1985 (Rea and
absorptio the water __
ffirmed During
n content
Year : 2020 the Work
)
To know
Wet Before
the IS 5640 /IS
Aggregat and
Strength __ 2386 : Part-
e impact During
of the 4
Value the Work
Aggregate
To know
Deleterio the Before
us percentage and
__ -
Constitue of During
nts deleteriou the Work
s
Before
Field
To know IS 2720- and
Compacti __
the MDD Part : 28 During
on
the Work
Absolute Before
To assess
Viscosity IS 1206 : and
its __
@ 60̊ C Part 2 : 2022 During
consistenc
Poises the Work
y,
Kinemati Before
gradation,
BITUM c IS 1206 : and
2 viscosity, __
EN Viscosity Part 3 : 2021 During
temperatur
@ 135̊C the Work
e
Before
Penetrati susceptibil
IS 1203 : and
on @ ity, and __
2022 During
135̊C safety.
the Work

138
 Before
Softening IS 1205 : and
__
Point 2022 During
the Work
Ductility
Before
@ 25̊C
IS 1208 : and
(After __
Part 1 : 2023 During
thin Film
the Work
oven test)
Before
Flash IS 1208 : and
__
Point Part 2 : 2023 During
the Work
Before
Solubility IS 1216 : and
__
test 2023 During
the Work

WATER CONVERYOR SYSTEM(PIPES)

IS 8329 :
To know Before
2000
Ovality the and
Tape __ (Reaffirmed
DUCTI Test roundness During
2005)
LE of the pipe the Work
1.
IRON
Hydro- socket Leakages, IS 8329 : Before
Static and sweating 2000 and
__
Pressure rebated or any (Reaffirmed During
Test joints defect 2005) the Work
socket
Leakages, IS 3597 :
Hydro- and
sweating 1998 Before
static rebated __
or any (Reaffirmed the work
test, joints
defect 2003)
Three- To know IS 3597 :
Crack
edge crushing 1998 Before
CONCR measurin __
bearing force (Reaffirmed the work
2. ETE g gauge
test 2003)
PIPE
Brush,
Sealant,
IS 3597 :
Permeabi glass To know
1998 Before
lity test, tube, the __
(Reaffirmed the work
metal seepage
2003)
cap

139
 IS 3597 :
Straightn Gauge, To verify
1998 Before
ess test edge X Dimensio __
(Reaffirmed the work
n
2003)
Mechani
cal
convecti IS 3597 :
Absorpti on To check 1998 Before
__
on test oven, cracks (Reaffirmed the work
Weigh 2003)
Balance

Chemical To Know __ AS Per IS For

Composit Percentag 2002 :2009 every
ion e of Consign
Chemical ment
Compositi
on in the
Steel
Mechanic Universa To Know __ AS Per IS For
al l Testing Ultimate 2002 :2009 every
Propertie Machine Tensile Consign
s Strength, ment
Yield
Stress
(YS) ,%
Elongatio
n Gauge
Length
MS Thicknes Vernier To know __ As Per IS0 For
3.
PIPE s of Plate Caliper the 7452-1984 every
Thickness Consign
of Steel ment
Plate
Ovality To know IS
Test the 3589:2001 During
Tape __
roundness Reaffirmed the work
of the pipe 2022
Straightn IS
Taut To verify
ess 3589:2001 During
string Dimensio __
Reaffirmed the work
or wire n
2022
Ultra To detect
Sonic Ultra internal As per
Testing sonic flaws or to ASME 2010 During
__
Testing characteri Section VIII the work
Machine ze
materials.

140
 Radiogra For
phy examining
IS 2595-
Testing the
2008,IS
internal
Radiogra 4853-
structure During
phy __ 1982,IS
of any the work
Camera 4260:2001&
componen
ASME SEC
t to
V
identify its
integrity.
Hydro IS
Testing 3589:2001
Examinati
Pressure Reaffirmed
on for
Gauges, 2022 During
leaks & __
Rubber IS the work
Soundness
Gasket 5822:1994
of Pipe
Reaffirmed
2014
Sand To
Blasting Hopper, Remove IS 5894 :
During
Pressure Rust on __ 2018
the work
gauge pipe
surface
Epoxy To avoid
Coating corrosion
Elco IS During
as well as __
meter 3589:2001 the work
erosion of
bare pipes.

Note:
 The list of equipment shown above is indicative. Additional equipment if any,
required for successful completion of work Shall be provided or arranged by
the contractor.
 The cost of laboratory building including services, essential supplies like water,
electricity, sanitary and their maintenance and cost of all equipment, tools,
materials, labour and incidentals to perform tests and other operations of
quality control according to the specifications requirement shall be deemed to
be incidental to the work and no extra payment shall be made for the same.
 The Engineer-In-Charge / Agreement concluding authority shall verify the lab
equipment procured by the agency. If the agency has not procured lab
equipment then the Engineer-In-Charge / Agreement concluding authority shall
procure the equipment and recover the cost of equipment from the agency
payments.

141
 QUALITY CONTROL CHECKS TO BE PERFORMED ON MAJOR COMPONENTS
OF EM (ELECTRO - MECHANICAL) & HM (HYDRO-MECHANICAL) EQUIPMENT
(T= Type Test; R=Routine Test: N.A =Not Applicable)
Dim
ensi
Ins
on Fa Mate
ulat Hi
Al ult rial
ion Fun M Fa gh
Che T Rating cu Tem Effi Com
Sl. M resi ctio od ult Vo
Item/Equip cks y (Capacity, rre perat cien posit
N ak stan nal el Cu lta
ment Len p Voltage,Cu nt ure cy ion
o. e ce Che Te rre ge
gth, e rrent) rat tests tests chec
(IR cks st nt tes
Wei in ks/te
Val ts
ght, g sts
ue)
Size
Etc
A.TESTS & CHECKS TO BE DONE AT WORKS (EX-FACTORY)
Startor & N
1. Rotor of R R R R R R R . T T T T T
Motor A
N. N. N. N. N.
2. Pumps R R R R R T N.A T
A A A A A
Guide
vanes,Sh
afts,impe
ller, N
N. N. N. N. N.
3. valves,dr R R R R R . N.A T
A A A A A
aft tube A
gates,pre
ssure
mains
Oil &
Air
receivers
of guide N
N. N. N. N. N.
4. vanes/Di R R R R R . N.A T
A A A A A
scharge A
valve
operating
system
Air
Compres N
5. sors, Air R R R R R R R . T
Receiver A
s
N
Transfor
6. R R R R R R R . T T T T T
mers
A
N
Control
7. R R R R R R R . T T T T T
Panels
A
N
H.T
8. R R R R R R R . T T T T T
Panels
A

142
 N
L.T
9. R R R R R R R . T T T T T
Panels
A
N
10. Cables R R R R R R R . T T T T T
A
E.O.T
N
cranes &
11. R R R R R R R . T T T T T
Gantry
A
Cranes
N
12. Lifts R R R R R R R . T T T T T
A
Lighting N
13. Equipme R R R R R R R . T T T T T
nt A
Air
Conditio N
14. ning R R R R R R R . T T T T T
equipme A
nt
Ventilati N
15. on R R R R R R R . T T T T T
System A
N
Capacito
16. R R R R R R R . T T T T T
r bank
A
Switch
yard
equipme
nt like
breakers, N
N.
17. C.Ts R R R R R R R . T T T T
A
P.Ts A
L.As
isolators
and earth
switches
Note: Testing Procedures for items shall be as per the Indian Standard Specificatoins and
the manuals of respective manufacturing companies

143
 QUALITY CONTROL CHECKS TO BE PERFORMED ON MAJOR
COMPONENTS OF EM ( ELECTRO - MECHANICAL) & HM ( HYDRO-
MECHANICAL) EQUIPMENT (T= Type Test ; R=Routine Test : N.A =Not
Applicable)
Dimen
Rating
sion Al Insulat
(Capac Fault
Checks ion High
ity, Functi Curr Efficie
Sl.N Length Ma Ty resista Volt
Item/Equipment Voltag onal ent ncy
o . , ke pe nce age
e, Checks ratin tests
@nvv

Weight (IR tests

Curre g
, Size Value)
nt)
Etc
B. TESTS & CHECKS TO BE DONE AT SITE (DURING /AFTER ERECTION)
Startor &
1) R R R R R R T T T
Rotor of Motor
2) Pumps R R R R N.A R N.A N.A N.A
Guide
vanes,Shafts,i
mpeller,
3) valves,draft R R R R N.A R N.A N.A N.A
tube
gates,pressure
mains
Oil & Air
receivers of
guide
4) vanes/Discharg R R R R N.A R N.A N.A N.A
e valve
operating
system
Air
5) Compressors, R R R R R R
Air Receivers
6) Transformers R R R R R R T T T
7) Control Panels R R R R R R T T T
8) H.T Panels R R R R R R T T T
9) L.T Panels R R R R R R T T T
10) Cables R R R R R R T T T
E.O.T cranes
11) & Gantry R R R R R R T T T
Cranes
12) Lifts R R R R R R T T T
Lighting
13) R R R R R R T T T
Equipment
Air
14) Conditioning R R R R R R T T T
equipment
Ventilation
15) R R R R R R T T T
System
16) Capacitor bank R R R R R R T T T

144
 Switch yard
equipment like
breakers,C.Ts
17) R R R R R R T T N.A
P.Ts L.As
isolators and
earth switches
Note: Testing Procedures for items shall be as per the Indian Standard Specifications and
the manuals of respective manufacturing companies

145
 THE SEQUEL OF TESTS FOR THE PUMPS, MOTORS AND ASSOCIATED
AUXILIARIES
S. REMARKS
No. EQUIPMENT TESTING/VERIFICATIONS TO BE DONE
nvv
/ STATUS
PUMP AND ASSOCIATED AUXILIARIES
1. Horizontal Alignment
2. Center Alignment
3. Elevation Verification as per approved
drawings
4. Physical Dimension verification before and
1. DRAFT TUBE after concrete encasement
5. Drainage/De-watering/Pressure relief/
Instrumentation piping arrangement
verification as per approved drawings
6. Dye penetration test
7. Ultrasonic Test
1. Horizontal Alignment
2. Centre Alignment w.r.t Draft tube Center
3. Physical Dimensional verification
2. SPIRAL CASING
4. Elevation verification as per approved
drawings - Before and after concrete
encasement
5. Drainage/De-watering/Pressure
relief/Instrumentation piping arrangements
verification as per approved drawings.
3. PITLINER
6. Dye penetration test
7. Ultrasonic Test
8. Hydro Test
4. Guide vane 1. Alignment verification as per approved
Apparatus drawings
5. Pump 2. Functional test
Impeller/Turbine 3. Full Load test to be carried out after
commissioning
4. Performance Test After wet run
6. Guide/Thrust 1. Physical Inspection and Alignment
Bearing verification as per approved drawings and
draft tube center.
2. Visual/Grade Inspection of Lubricant level
3. Temperature Test
4. Vibration Test to be carried out after
commissioning
7. Shaft Seal Visual and Physical Observation for abnormal
(Mechanical Seal) leakages
8. Pump Shaft 1. Alignment verification as per approved
drawings and draft tube center.
2. Functional test
3. Full Load test to be carried out after
commissioning
9. Pump Cover/Bracket 1. Physical Inspection and Alignment

146
 2. Verification as per approved drawings and
draft tube center

10.Pump Mounted 1. Visual Inspection

Instruments, safety 2. Functional Check
devices & 3. Set Point Verification as per approved
Accessories drawings
MOTOR AND ASSOCICATED AUXILIARIES

11. Synchronous motor 1. Physical Inspection and Alignment verification

complete with as per approved drawings, shaft and draft tube
instruments and center
controls and safety 2. Winding Resistance test
devices 3. Insulation Resistance test
4. High Voltage test
5. Physical verification of accessories
6. Phase Sequence test
7. Phase Balance test
8. Temperature verification
9. Shaft voltage test
10. Bearing Housing vibration
11. Noise level measurement
12. Air gap measurement
13. Breaking panel functional test
14. No-Load functional test
15. Load test
Switch Gear
12 Static excitation 1. Physical verification of components
equipment and AVR 2. Functional test
3. Test sequence
4. Load test
13 LCI Starting 1. Physical verification of components
Equipment 2. Functional test
3. Test sequence
4. Load test
14 Control & Relay 1. Physical Inspections of all the relay panels
Panel 2. Configuration of relays
3. CT & PT Calibrations
4. Functional Interlocks tests
5. Internal wiring and ferruls verification
6. Check for proper earthings
15 11 KV Switch Gear 1. Bus Bar resistance test
Panels 2. IR Test
3. Physical Inspection of all components
4. Mechanical functional test of breakers
5. Load and Noload TNC operations of breakers
6. Functional Interlock tests
7. Earthing

147
16 415V 1. Bus bar resistance test
SAB/UAB/Emergen 2. IR test
cy Panels 3. Physical Inspection of all components
4. Mechanical functional test of breakers
5. Load and No load TNC operations of breakers
6. Functional Interlock tests
7. Earthing
17 Batteries 1. Individual Voltage test
2. Combined battery set Voltage
18 Battery Chargers 1. Float cum Boost Charge test
2. Full load discharge cycle test
19 DCDB 1. Physical Inspection of components
2. Functional Interlock test
20 Instruments & 1. Physical Inspection of components
SCADA Automation 2. Calibration of all the instruments
3. SCADA user interface test
4. Verification of all parameters in SCADA
5. Individual Component automation test
6. Final test of run, stop and trip sequences from
SCADA
21 Power Cables 1. Winding resistance test
2. IR test before and after laying
3. Tagging of cables
22 Control Cables 1. Visual inspection and conductivity test
2. Tagging of cables
23 11 KV Bus Duct and 1. Resistance test
Termination panels 2. IR Test
24 Cable racks and 1. Earthing of Trays and racks
Trays 2. Checks and removing of sharp edges
3. Tri foiling and Neat dressing arrangement of
cables
4. Tagging of trays
25 Pump House 1. Physical inspection of components as per
Lighting and LDBs approved drawings
26 Pump House 1. Earth resistance measurements at all locations
Earthing and 2. Check resistance at HT, LT and electronic earth
Grounding pits
27 250KVA DG Set and 1. Physical inspection of components as per
AMF Panel approved drawings
2. Full Load Test
3. Consumption test
4. AMF auto cutoff/on functional test
28 Station compressed Full Load test
air system with
auxiliaries
29 Fire Fighting System 1. Physical Inspection of Components as per
approved drawings
2. Check the fire extinguishing cylinders
3. Full Load operation of firefighting motors

148
 30 Ventilation system 1. Physical Inspection of Components as per
approved drawings
2. Air Quality check
31 Air Conditioning 1. Physical Inspection of components as per
System approved drawings
2. Operation verification of the equipments
AUXILIARY MOTORS
32 Drainage & 1. Physical Inspection of components as per
Dewatering System approved drawings
33 Cooling water 2. Load and No-Load tests
System 3. Checking of the flow as per the equipment
34 Service water system under protection manuals and approved
drawings
TRANSFORMERS
35 SFC Transformers 1. Physical Inspection of components as per
36 Unit Auxiliary approved drawings.
Transformers 2. IR Test.
37 Excitation 3. Functional test on marshalling box/
Transformers Transformer protection relay.
4. Load test and corresponding voltage, Current
readings.
CRANES
38 EOT Crane 1.
Physical Inspection of Components as per
39 Gantry Crane approved drawings
40 30T Mobile Crane 2. Load test
3. Over Load test
4. Speed Measurement in all directions
5. Span verification
6. Brakes Limit switches check
7. Operation test for control panels
41 HOPD Values & 1. Physical Inspection of components as per
Power Pack System approved drawings
2. Load test
3. Operational test for Power pack system
4. Operational test for HOPD Valve
42 Draft Tube Gates 1) Physical Inspection of Components s per
43 Trash rack Gates approved drawings
2) Smooth operation in No Load Conditions
3) Smooth operation in full Load Conditions

*Note*

 Sequence of testing and Testing Procedures for items shall be as per the Indian Standard
Specifications and the manuals of respective manufacturing companies

 The inspection and testing procedures of the equipment involved in the nature of work may
vary according to the terms and conditions.

149
 ERECTION OF ELECTRO MECHANICAL EQUIPMENT & TESTING
Description Testing
1. Draft Tube Water Inlet
Tests on DT Liner
2. Draft Tube Channel
1. DYE Penetration Test (DPT) Conducted
3. DT Liner Segments
for Longitudinal and Cross sectional joints
4. DT Liner 7 Segments
of DT Liner Segments
5. DT Elbow Liner After Erection
6. DT Cone
Tests on Stay Ring
7. Lowering of Stay Ring
1. DYE Penetration Test (DPT)
8. Stay ring After Joining Two
2. Ultra Sonic Test (UT) Conducted after
joining two stay ring segments to find any
defect in welding
9. Spiral Casing
Tests on Stay Ring
1. DYE Penetration Test (DPT)
2. Ultra Sonic Test (UT) for Each joint (LS&
CS)
3. Hydro Test.
10. Foundation Ring
Tests on Foundation Ring
1. DPT after welding of foundation ring with
DT Cone
11. Erection of Top Cover
Tests on Pitliner
12. Erection of Guide Vane
1. After joining two halves of pitliner DPT is
13. Pimp Pit Liner
performed.
2. Placing Pitliner on the stay ring & after
welding DPT Test is Performed.
3. DPT is performed on servo motor
foundation plates.
14. Bottom Bracket & Stator Sole plates
Tests on Stator
15. Erection of Pump Impeller with Shaft
1. Ultra sonic Test (UT) is performed after
16. Erection of Regulating Ring
brazing at stator bar joints.
17. Placing of bottom bracket
2. High Voltage test is performed after
18. Motor Bottom Shaft
bottom bars assembled.
19. Thrust Pad Assembly in Bottom
3. High Voltage test is performed top bottom
Bracket
bars assembled.
20. Mechanical brake & Jack Assembly
4. Final HV Test is conducted at 23 KV
21. Fixing of Main Discharge Value
before lowering.
22. Erection of Stator
23. Insulation resistance test (HV Test)

150
 2.4 FREQUENCY OF TESTING

S. Test Frequency of Test Purpose Test Designation

No
SOILS
1. Grain size analysis for One test per day/for every To know the As per IS-2720-IV-
classification 3000 Cu.m classifications of 1975
soil actually put in
the embankment
2. Atterberg Limit test One test per day -do- IS-2720-V-1970
3. Specific Gravity One test per day -do- IS-2720-III-1964
4. Field Density and One test for every 1500 m3 of To determine the IS-2720-XXVIII-
Moisture content earth work and at least one placement density 1974
test in each layer laid on and moisture IS-2720-XXIX-
embankment. content. 1966
IS-2720-XXXIII-
1971
5. In-situ permeability One test in one week or every To determine IS-2720-XVII-1966
Test 3m of embankment height or permeability
for 20,000 m3 characteristics of the
fill material
6. Triaxial Shear Test One test in one week or every To know the shear IS-2720-XII-1975
3m of embankment or for characteristics of fill
20,000 m3 material (in-situ)
7. Consolidation Test 1 set of 3 samples in every To know the IS-2720-XV-1965
6m height of embankment or settlement rate and
for 30,000 m3 or once in ten its magnitude
days
8. Standard Proctor Test One test per day for To determine MDD IS-2720-VII-1970
individual Borrow Area and OMC of the soil
and compare the
results with
Laboratory value
9. Moisture content One test in each sample To know the IS-2720-II-1975
moisture content of
the sample
10. Shrinkage Factor One test in one week or 5 To determine IS-2720-PartVI-
mtrs of embankment height. shrinkage limits 1972
FILTERS
11. Grain Size Analysis One test for every 200 m3 of To find % of the IS-2386-Part I
filter (sand) One test for D10, D15, D30, D50,
every 200 m3 of filter D60 and D85 grain
(Aggregate) sizes of materials
12. Clay lumps and One test for every 200 m3 To find out clay IS-2386-Part II
organic impurities (sand) One test for every 200 lumps & Organic
m3 (Aggregate) impurities level

151
S.
Test Frequency of Test Allowable Limits Test Designation
No
1 CEMENT
a) Chemical
i) Alkalies a) IS : 269-1989
ii) Minor, Major OPC < 0.60% b) IS : 1489-1991
For each consignment
oxides by PPC < 0.70% c) IS : 4032-1985
Calorimetry PPC/OPC <0.05%
iii) Chloride
Not < 2250 cm2/gm
Not > 10mm
b) Physical
i) Fineness Penetration up to 5
ii) Soundness (Le to 7 mm from base.
Chatelier) IT – Not <30 min
iii) Consistency FT – Not >600 min
iv) Setting time 3 days – 160 a) IS : 269-1989
(Initial & Final) For each consignment kg/cm2 b) IS : 1489-1991
v) Compressive 7days – 220 kg/cm2 c) IS : 4031 1988
Strength 28 days –
vi) Heat of 330kg/cm2
Hydration PPC 7 days -
vii) Drying 65Cal./gm
Shrinkage OPC 28 days-
75Cal./gm <
0.15%

S. Test
Test Frequency of Test Purpose Designation Allowable Limits
No
2 FINE AGGREGATE
One Test for each To know grain
150 m3 of sand size and the
Sieve Analysis IS : 2386 –
1 used in fineness 2.2 to 3.2
(Fineness Modules) Part - I- 1963
concrete/Weekly modules of
Once sand
One Test for each
150 m3 of sand
used in concrete To Utilize the
IS : 2386 – Allowable limit of
Unit weight and (also once in a shift data for Mix
2 Part - III- bulkage of sand is
Bulkage of sand or for every design
1963 20 %
consignment. / computation
Monthly once

One Test for each

IS : 2386 –
150 m3 of sand To assess the
3 Organic Impurities Part - II-
used in concrete quality of sand
1963

152
 One Test for each
Loss not > 10%
150 m3 of sand IS : 2386 –
To assess the after 5 cycles of
4 Soundness used in concrete/ Part - V-
quality of sand immersion in
Yearly once or 1963
Na2SO4
change of source
One Test for each To assess the Not > 3% for
150 m3 of sand silt content IS: 2386 – natural FA and
5 Silt content
used in concrete/ present in the 1963 not > 5% for
weekly once sand. crushed FA
One Test for each To Utilize the
Specific gravity, IS: 2386 –
150 m3 of sand data for Mix
6 Moisture content Part - III-
used in concrete/ design
and absorption 1963
weekly once computations

S. Test Allowable
Test Frequency of Test Purpose Designation Limits
No
3 COARSE AGGREGATE
One Test for each To know
150 m3 of sand gradation and IS : 2386 –
1 Sieve Analysis
used in concrete/ percentage of Part - I- 1963
Weekly Once various size
Specific Gravity, Not>2.6
One Test for each To Utilize the
Bulk density, IS : 2386 – Not more than
150 m3 of sand data for Mix
2 Moisture content, Part - III- 5% by weight
used in concrete/ design
absorption & silt 1963 Not > 3%
Weekly Once computation
content
One Test for each Loss not > 12%
150 m3 of sand To assess the IS : 2386 – after 5 cycles of
Soundness (Sodium
3 used in concrete/ quality of coarse Part - V- immersion in
sulphate method)
Yearly once or aggregate 1963 Na2SO4
change of source
Wearing
One Test for each
surfaces: Loss
150 m3 of sand To assess the
Abrasion, Impact IS: 2386 – Not >30%, Non
4 used in concrete/ quality of coarse
and crushing value Part-IV -1963 wearing
Yearly once or aggregate
surfaces
change of source
not>45%
Wearing
One Test for each
To assess the surfaces: Loss
150 m3 of sand
Hardness IS: 2386 – Not >30%, Non
5 a) Abrasion Value used in concrete/
property of Part-IV -1963 wearing
Yearly once or
coarse aggregate surfaces
change of source
not>50%
To assess the Wearing
Toughness IS: 2386 – surfaces: Loss
b) Impact value As Specified
property of Part-IV -1963 Not >30%, Non
coarse aggregate wearing

153
 surfaces
not>45%
To assess the
Wearing
crushing IS: 2386 –
c) Crushing Value As Specified surfaces: Loss
property of Part-IV -1963
Not >30%
coarse aggregate
Combined Flakiness
Weekly twice/ To know the IS 2386 (Part
Index & Elongation Not > 40%
source change particle shape 1): 1963
Index
One Test for each To assess the IS: 2386 –
Organic impurities
5 150 m3 of sand quality of coarse Part - II- Less than 1%
(Mica content)
used in concrete aggregate 1963
Falling in left
side of Sc/Re
To know the
Twice in one Curve…Innocuo
Alkali reactivity innocuous or IS: 2386–
working season/ 5 us
6 (Alkali- Aggregate deleterious Part- VII-
times yearly or Falling in right
reactivity) nature of 1963
source change side of Sc/Re
aggregate
Curve…
deleterious
To know the
Twice in one IS: 238 – Deleterious
Petrographic deleterious
7 working season/ / 5 Part- VIII- constituent shall
examination constituents and
times yearly 1963 not exceed 5%
silt in aggregate

S. Test Allowable Limits

Test Frequency of Test Designation
No
4 Gravel
i) Size of Gravel Not larger than ¾’’
1 ii) Liquid Limit For each stack IRC: 19-1977 <20%
iii) Plasticity Index <6%
6 to 8
Water Two sample for IS: 3025 Part II Not > 200 mg/l
2 pH value, Organic, In-Organic each source IS: 3025 Part 18 Not > 3000 mg/l

Not > 400 mg/l

Plain concrete: Not >
IS: 3025 Part 24
3 Sulphates, Chlorides 2000 mg/l
IS: 3025 Part 32
RCC Work: Not >
1000 mg/l

Not > 2000 mg/l

4 Suspended solids IS: 3025 Part 17

154
5 RR STONE
i) Abrasion value IS: 1124 - 1974 Not to exceed 6 %
Granite – 1000
ii) Crushing strength IS: 1124 – 1974
kg/cm2
For each quarry Basalt – 400 Kg/cm2
iii) Specific Gravity IS: 1124 – 1974 2.60
iv) Water Absorption IS: 1124 - 1974 Not to exceed 5 %
v) Durability IS: 1124 - 1974
6 REINFORCEMENT
For each
Weight
consignment/
Diameter
1 bend test one Refer the table
Ultimate Test IS: 1786 – 1985
tensile test for below for allowable
Strength IS: 432 – 1982
every 5 tonnes or limits.
Yield Stress
less or every 6000
Elongation
m2 of fabric

Allowable Limits for Reinforcement Bars @nvv

Characteristic
Minimum elongation
strength (yield
Ultimate tensile on gauge length of 5.65
Types of Reinforcement stress of 0.2 %
stress, N/mm2 X √ Cross – sectional
proof stress
area (%)
N/mm2
Mild steel of grades
Upto 20mm -I 250 410
23
>20mm to 50mm -II 240 410
Upto to 20mm 225
370 23
>20mm to 50mm-II 215
Medium Tensile Steel
350 540
upto 16mm
340 540 20
17-32mm
330 570
33-50mm

10 % more than the

Cold worked deformed actual 0.2 % proof
415 14.5
bars stress but not less
550 - 6% more than than 485 N/mm2
actual 0.2% proof stress
but not less than 585 8 % more than the
N/mm2 actual 0.2 % proof
500 550
stress but not less
than 545 N/mm2
15 % higher than the
Hot Rolled 412 yield stress 14.5

155
 SAIL –MA of grades
300 HY 300 440-560 20
350 HY 350 490-610 20
410 HY 410 540-660 19

Frequency to Testing Cement Mortar, Masonry and Concrete.

Test
S. No Test Frequency of Test Allowable Limits
Designation
Quantity of
Number
Concrete in
of
the work,
samaples
m3
1-05m3 1
3
06-15m 2
3
16-30m 3
Cube Test for 3
31-50m 4
1 IS: 456-2000
concrete 4 plus one
additional
sample
3
51m and for each
above additional
50m3 or
part there
of
Cube test for
3 tests per each grade of IS 2250 – 1981 Size of cube is 50
2 cement mortar
mortar per day Appendix - A cm2
in masonry
Not greater than
Permeability 2.5X10 -8 mm per
3 tests on cement Once in a week IS: 3085 - 1965 sec, for rich mortar
mortar & 4.8X10 -8 for lean
mortar.
Permeability At least two holes in Not greater than 2.5
tests on every block for every lugeons in masonry
IS: 11216 –
4 masonry lift, one in upstream and in CM 1:3 and 5
1985
applicable for one downstream in lugeons in masonry
masonry dams) staggered fashion in CM 1:4 for dams
One test in each shift on IS: 1199-1959/
5 Slump test at frequent intervals to IS: 1199 Part As per Mix Design
check workability 2- 2018

156
 PRESSURE MAINS, DUCTILE IRON PIPES & CONCRETE PIPES

Frequency of Test Designation Allowable Limits

S. No. Test
Test
Pressure Mains
AS Per IS 2002 :2009,
Chemical For Every Conforming to Table 2
1 IS 3589:2001
Composition Consignment (Clause: 8.1 and 8.2)
Reaffirmed 2022
AS Per IS 2002 :2009,
Mechanical For Every Conforming to Table 4
2 IS 3589:2001
Properties Consignment (Clause: 9.1)
Reaffirmed 2022
Thickness of
3 Each Plate As Per IS0 7452-1984 Clause 3.1
Plate
Ovality shall not exceed
4 Ovality Test IS 3589:2001 1 % of the
Each Pipe
Reaffirmed 2022 specified outside diameter
for pipe.
Finished pipe shall not
deviate from straightness
5 Straightness IS 3589:2001
Each Plate by more than 0.2 percent
Reaffirmed 2022
of the total length.

Imperfections which
Ultra Sonic As per ASME 2010 produce a response greater
6 Each Pipe/ Joint
Testing Section VIII than 20% of the reference
level shall be investigated.
IS 2595-2008, IS 4853-
Radiography 1982, IS
7 Each Pipe/ Joint As Per Agreement
Testing 4260:2001&ASME
SEC V
IS 3589:2001
Not less than 1.5 times the
8 Hydro Testing Reaffirmed 2022
Each Pipe design Pressure and As
IS 5822:1994
Per Agreement
Reaffirmed 2014
9 Sand Blasting IS 5894: 2018
Each Plate As Per Agreement
10 Epoxy Each Pipe IS 3589:2001 As Per Agreement

DUCTILE IRON PIPES

As per
1 Mechanical IS 8329: 2000 As Per Clauses 10 of IS
Manufacturer
Tests (Reaffirmed 2005) 8329
Manual
As per
2 IS 8329: 2000
Ovality Test Manufacturer As Per Table 8 of IS 8329
(Reaffirmed 2005)
Manual

157
 As per
3 Hydro-Static IS 8329: 2000
Manufacturer As Per Annex E (Table 1)
Pressure Test (Reaffirmed 2005)
Manual
As per
4 IS 8329: 2000 As Per Annex A (Clause
Zinc Coating Manufacturer
(Reaffirmed 2005) 16.2) of IS 8329
Manual
As per
5 Cement Mortar IS 8329: 2000 As Per Annex B (Clause
Manufacturer
Lining (Reaffirmed 2005) 16.3) of IS 8329
Manual
As per
6 Bituminous IS 8329: 2000 As Per Annex C (Clause
Manufacturer
Coating (Reaffirmed 2005) 16.2) of IS 8329
Manual
CONCRETE PIPES (NP-Non-Pressure Pipes)
As per As Per Clause 7 of IS
1 IS 3597: 1998
Hydro-static test, Manufacturer 3597: 1998
(Reaffirmed 2003)
Manual (Reaffirmed 2003)
As per As Per Clause 5 of IS
2 Three-edge IS 3597: 1998
Manufacturer 3597: 1998
bearing test (Reaffirmed 2003)
Manual (Reaffirmed 2003)
Permeability As per As Per Clause 8 of IS
3 IS 3597: 1998
test, Manufacturer 3597: 1998
(Reaffirmed 2003)
Manual (Reaffirmed 2003)
As per As Per Clause 9 of IS
4 Straightness test IS 3597: 1998
Manufacturer 3597: 1998
(Reaffirmed 2003)
Manual (Reaffirmed 2003)
As per As Per Clause 6 of IS
5 IS 3597: 1998
Absorption Test Manufacturer 3597: 1998
(Reaffirmed 2003)
Manual (Reaffirmed 2003)

The actual frequencies shall be determined by the Engineer-in-charge to suit the nature and
variability of material placed and the rate of fill placement with the objective of ensuring best quality
control and quality construction.

The Actual Frequency of testing and tests to be conducted shall be decided by Engineer-in-
Charge as per the nature of work and requirement.

158
 2.5 LIST OF EQUIPMENT FOR WORKS COSTING LESS THAN 2 CRORES

11.0. SOILS:

1. (i) Electronic weigh Balance 6 kg, (ii) Electronic weigh Balance 600 gmx 0.01 g,
(ii) Sieves 4.75 mm, 2.36 mm, 1.18 mm, 600 micron, 300 micron, 150 micron and 75
micron, Pan and cover,
2. Sieve Shaker, Motorized, with Built-in Digital Timer,
3. Liquid Limit Device,
4. Plastic Limit set,
5. Shrinkage Limit Set,
6. Specific Gravity Test,
7. Hydrometer, Analysis with all accessories,
8. Filter paper,
9. Compaction Test Apparatus for heavy compaction,
10. (i) Cylindrical Core Cutter, made of steel 100 mm dia x 130 mm long along with dolly
including Rammer, with Steel Rod, Straight Edge, Trowel, Tray etc.,
(ii) Sand Pouring Cylinder Apparatus, 100 mm Dia. The equipment consists of the
following parts: sand pouring Cylinder, Cylinder Calibration Container 100 mm ID x 150
mm height, Metal tray size 30x30x4 cm, with 10cm central hole,
11. Relative Density Apparatus and
12. Sand Pouring Cylinder Apparatus
11.1 COARSE AGGREGATE:
1. (i) Sieves for Coarse Aggregate,
2. Sieves G. I. Frame 30 cm dia x 80 mm, 40 mm, 20 mm, 12.5 mm, 10 mm, 4.75 mm,
2.36 mm, pan and cover,
(ii) Electronic weigh balance 20 kgs
(iii) Thickness Gauge with ISI Certification Mark IS:2386 (Part I)
(iv) Length Gauge with ISI Certification Mark IS:2386 (Part I)
3. (i) Sieve G. I. Frame 45 cm dia x 31.5 mm, 16 mm, 8.6 mm.
11.2 CEMENT:
1. (i) Vicat Apparatus with ISI Certification Mark, IS:5513, fitted in Aluminum Box,
(ii) Consistency Plunger (in Plastic Case),
2. Le-Chatelier Mould, with ISI Certification MarkI S:5514, each and
3. Cube moulds for cement testing

159
11.3 CONCRETE:
1. Slump Test Apparatus with testing rod and base plate,
2.PH Balance,
3. (i) Mould, Cast Iron, of 150 mm x150 mm x 150 mm Cube with ISI Certification Mark,
(ii) Tamping Rod, Steel, 16 mm dia x 600 mm length with ISI Certification Mark,
IS:10086 and
(iii) Digital Compression Testing Machine, Capacity 1000 KN.
11.4 MORTAR:
1. Moulding tray for cubes Beaker (for taking water) including Tamping Rod, Steel, 16
mm dia and Stop Watch 'Mechanical' 1/5 sec.
2. Mould, Cast Iron, of 75 mm x75 mm x 75 mm Cube with ISI Certification Mark.
11.5 GENERAL:
1. Auto level 24X with stand and 6 m staff,
2. Spring Balance 50 Kg,
3. Measuring Tapes,
4. Rodometer PVC Wheel,
5. Oven and
6. Thermometer.
Note:
1. The list of equipment shown above is indicative. Additional equipment if any, required for
successful completion of work Shall be provided or arranged by the contractor.
2. The cost of laboratory building including services, essential supplies like water, electricity,
sanitary and their maintenance and cost of all equipment, tools, materials, labour and incidentals
to perform tests and other operations of quality control according to the specifications
requirement shall be deemed to be incidental to the work and no extra payment shall be made
for the same.
3. The Engineer-In-Charge / Agreement concluding authority shall verify the lab equipment
procured by the agency. If the agency has not procured lab equipment, then the Engineer-In-
Charge / Agreement concluding authority shall procure the equipment and recover the cost of
equipment from the agency payments.
4. Advanced Equipment can be used for accuracy of work in acceptance with agreement authority.

160
 2.6 LIST OF EQUIPMENT FOR WORKS COSTING MORE THAN 2 CRORES

12.0 SOILS:

1. (i) Electronic weigh Balance 6kg, (ii) Electronic weigh Balance 600gmx0.01g.
(ii) Sieves 4.75mm, 2.36mm, 1.18mm, 600micron, 300micron, 150micron and 75 micron,
Pan and cover
2. Sieve Shaker, Motorised, with Built-in Digital Timer
3. Liquid Limit Device,
4. Plastic Limit set
5. Shrinkage Limit Set.
6. Specific Gravity Test
7. Hydrometer, Analysis with all accessories
8. Direct Shear Test Apparatus 2 kN capacity
9. Tri-axial Shear test Apparatus
10. Swell Test Apparatus.
11. Free Swell Test Apparatus
12. Consolidation Apparatus.
13. Compaction Test Apparatus for light compaction
14. Compaction Test Apparatus for heavy compaction.
15. (i) Cylindrical Core Cutter, made of steel 100mm dia x 130mm long alnog with dolly
including Rammer, with Steel Rod, Straight Edge, Trowel, Tray etc.,
(ii) Sand Pouring Cylinder Apparatus, 100mm Dia The equipment consist of the following
parts: sand pouring Cylinder, Cylinder Calibration Container 100mm ID x 150mm height,
Metal tray size 30x30x4 cm, with 10cm central hole.
16. Rapid Moisture Meter.
17. Relative Density Apparatus.
18. In-situ Permeability test Apparatus including soil extraction etc., complete.
19. Laboratory Permeability Apparatus.
20. Standard Penetration Test (SPT) Set.
21. Laboratory California Bearing Ratio Test Apparatus.
2.6.1 COARSE AGGREGATE:
1.(i) Sieves for Coarse Aggregate for road
2.Sieves G.I. Frame 30cm dia x 80mm, 40mm,20mm, 12.5mm, 10mm, 4.75mm, 2.36mm,
pan and cover

161
 (ii) Electronic weigh balance 20kgs
(iii) Thickness Gauge with ISI Certification Mark IS:2386 (Part I)
(iv) Length Gauge with ISI Certification Mark IS:2386 (Part I)
3. Alkali aggregate reactivity test scales
4. (i) Sieve G.I. Frame 45cm dia x 31.5mm, 16mm, 8.6mm.
(ii) Solution of sodium or magnesium sulphate.
5. (i) Sodium hydroxide.
(ii) graduated glass bottle.
6. Petrography by animation hammer.
7.(i) Aggregate Impact Tester.
(ii) Crushing Value Apparatus.
8. Los Angeles Abrasion testing machine with Counter.
9.Digital length comparator with air tight lid and rod.
2.6.2 CEMENT:
1. (i) Vicat Apparatus with ISI Certification Mark, IS:5513, fitted in Aluminum Box.
(ii) Consistency Plunger (in Plastic Case).
2. Le-Chatelier Mould, with ISI Certification MarkIS:5514, each.
3. Cube moulds of size 75mm x75mm x75mm for cement testing
4. Lab cement autoclave
5. Shrinkage bar mould
6. Vibrating machine
7. Length comparator
8.Prism mould (50x50x200), rod of 205mm
2.6.3 CONCRETE:
1. Slump Test Apparatus with testing rod and base plate.
2. PH Balance
3. (i) Mould, Cast Iron, of 150mmx 150mm x150mm Cube with ISI Certification Mark.
(ii) Tamping Rod, Steel, 16mm dia x 600mm length with ISI Certification Mark, IS:10086.
(iii) Digital Compression Testing Machine, Capacity 2000kN.
(iv) Universal Testing Machine.
4. U.S.P.V Machine. (Ultra Sonic Pulse Velocity)
5. Digital Rebound hammer.
6. Concrete Penetrometer, Spring Type.

162
 7. Core Drilling Machine Including with core bit 75mm, 100mm,150mm dia (Hilty)
including generator.
8.Concrete Mixer, Drum Type, Capacity 1 Cubic Feet.
9.Vibrating Table, 50 x 50cm for 4 moulds of 150mm cube.
2.6.4 MORTAR:
1. Moulding tray for cubes Beaker (for taking water) including Tamping Rod, Steel, 16mm
dia and Stop Watch 'Mechanical' 1/5 se.
2. Mould, Cast Iron, of 75mm x75mm x 75mm Cube with ISI Certification Mark.

2.6.5 TUNNELLING
1. Luxometer(lux)
2. Multi gas Detector (PPM)
3. Centre Hole Jack
4.Sound Pressure Level Meter
2.2.6 SHOT CRETING
1. RDP – (Round Determinant Panel) Test system.
2. GRP – (Ground Penetrating Radar Equipment).
3. Bond Strength tester
4. Air Meters
2.2.7 GENERAL:
1. Total station.
2. Auto level 24 X with stand and 6m staff.
3. Spring Balance 50 Kg.
4. Measuring Tapes.
5. Rodometer PVC Wheel.
6. Oven
7. Thermometer.
8. Burette
9. Measuring cylinders and flasks,
10.Radiography Facilities,
11. Mechanical weighing balance
12. Ultrasonic testing machinery
13. DP test kit
14. Vernier Calipers
15.Micrometer
16.Radiography film viewer
17. Inside meter
18.Elcometer

163
Note:
1. The list of equipment shown above is indicative. Additional equipment if any, required for
successful completion of work Shall be provided or arranged by the contractor as per agreement
or the instructions of Engineer-in-Charge.
2. The cost of laboratory building including services, essential supplies like water, electricity,
sanitary and their maintenance and cost of all equipment, tools, materials, labour and incidentals
to perform tests and other operations of quality control according to the specification’s
requirement shall be deemed to be incidental to the work and no extra payment shall be made
for the same.
3. The Engineer-In-Charge / Agreement concluding authority shall verify the lab equipment
procured by the agency. If the agency has not procured lab equipment, then the Engineer-In-
Charge / Agreement concluding authority shall procure the equipment and recover the cost of
equipment from the agency payments.
5. Advanced Equipment can be used for accuracy of work in acceptance with agreement authority.

164
 2.7 MONITORING THROUGH CONTROL CHARTS

Monitoring of quality control and assessment of the trend of quality control being exercised
by the Project Management is best done through control charts. Indian standards I.S: 397 (Parts I
to III) cover control charts for general and special application. These charts are based on
compressive strengths of cement and concrete tests specimens. Control charts for cement strengths
are for different test ages (i.e., 3, 7 and 28 days) and both for strengths of individual test and moving
average of five tests over periods of time control charts for concrete strengths are also constructed
in more or less the same manner as per cement. In addition to the test data, the control charts also
incorporate certain reference line constituting a frame work within which the degree of control
actually achieved is assessed and remedial measures initiated where called for. The reference lines
are termed the “Warning” and “Action Limits”. The warning and action lines provide feed-back
for timely remedial measures.

Preparation of Quality Control Reports and Control Charts is considered to be a vital step
towards the process of achieving good construction quality. The Central Charts should be used as
a dynamic tool and accordingly these should be prepared as a concurrent exercise as the work
proceeds. These should be constantly scanned to identify indication of any significant deviation in
quality and initiate the remedial action promptly.

STANDARD DEVIATION (I.S. 456 – 2000)

The estimated standard deviation of given grade of concrete can be calculated from the result
of individual tests of concrete, using the formula:

∑∆
𝑆
𝑛 1

Where Δ = The deviation of the individual test strength from the average strength
of ‘n’ samples, and

n = number of sample test results.

If at least 30 test results for a particular grade of concrete at site with the same materials and
equipment are not available, the standard deviation, S, for the corresponding degree of control, may
be assumed from the following tabulation, given IS: 10262 – 2019.

165
 Table 1: Assumed Standard Deviation (as per IS: 10262 – 2019)

Assumed Standard
S. No. Grade of Concrete
Deviation, N/mm2
1 M 10
3.5
2 M 15
3 M 20
4.0
4 M 25
5 M 30
6 M 35
7 M 40
8 M 45 5.0
9 M 50
10 M 55
11 M 60

Acceptance Criteria for Concrete: As per IS 456: 2000

The concrete shall be deemed to comply with strength requirement when both the following
conditions are met.
a) The mean strength determined from any group of four consecutive tests results complies
with the appropriate limits in column 2 of the following table.
b) Any individual test result compiled with appropriate limits in column 3 of the following
table.
Table 2: Characteristics compressive strength compliance requirements (as per amendment
No.4 May-2013 to Table 11 of IS 456 – 2000)

Specified Mean of the group of 4 Individual test

grade non-overlapping results in N/mm2
consecutive test results in
N/mm2
(1) (2) (3)
M15 and above ≥ fck + 0.825 x established ≥ fck – 3 N/mm2
standard
deviation (rounded off to
nearest 0.5N/mm2)
Or
fck± 3 N/mm2whichever is
greater.

166
NOTE:
1. In the absence of established value of standard deviation, the values given in the above
table may be assumed and attempt should be made to obtain results of 30 samples as
early as possible to establish the value of standard deviation.
2. For concrete of quantity upto 30 m3 (where the number of samples to be taken is less
than four as per the frequency of sampling given in 15.2.2 of IS 456) the mean of test
results of all such samples shall be fck + 4 N/mm2, minimum and the requirement of
minimum individual test results shall be fck-2 N/mm, minimum. However, when the
number of sample is only one as per 15.2.2 of IS 456, the requirement shall be fck + 4
N/mm2, minimum.
Flexure Strength:
When both the following conditions are met, the concrete complied with specified flexural
strength:
a) The mean strength determined from any group of four consecutive test results exceeds the
specified characteristic strength by atleast 0.3 N/mm2.
b) The strength determined from any test result is not less than the specified characteristic strength
less 0.3 N/mm2.
c) The flexure strength is determined by fcr = 0.7√fck in N/mm2.
d) Modulus of Elasticity of concrete can be assumed as follows
Ec =5000√fck , where E, is the short term static modulus of elasticity in N/mm2.
Actual measured values may differ by ± 20 percent from the values obtained from the above
expression.

INSPECTION AND TESTING OF STRUCTURES:

Inspection:

Immediately after stripping the formwork, all concrete shall be carefully inspected and any
defective work or small defects either removed or made good before concrete has thoroughly
hardened.

In case of doubt regarding the grade of concrete used, either due to poor workmanship or
based on results of cube strength tests, compressive strength tests of concrete on the basis of core
and / or load test may be carried out.

Core Test:

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 The point from which cores are to be taken and the number of cores required shall be at the
discretion of the Engineer-in-Charge and shall be representative of the whole of concrete concerned.
In no case, however, shall fewer than three cores be tested. Core shall be prepared and tested
described in IS: 516-2018 Part 4.
Concrete in the member represented by a core test shall be considered acceptable if the
average equivalent cube strength of the cores is equal at least 85 percent of the cube strength of the
grade of concrete specified for the corresponding age and no individual core has a strength less than
75 percent.
In case the core test results do not satisfy the requirements of or where such tests have not
been done, load test may be restored to.

Ex: In a concrete work, M15 (Fck = 15 N/mm2) is to be used. The assumed standard deviation for
this grade of concrete from table is 3.5 N/mm2. In the course of testing cubes, the following results
are obtained from a week’s production (average strength of 3 specimens) tested at 28 days in
N/mm2.
22.6, 21.7, 20.7, 20.6, 19.7, 13.2, 11.8, N/mm2.
Discuss the acceptance of the results

Sol: The individual test result should satisfy Col.3 of table 2, fck-3, i.e. 15-3 = 12 N/mm2

a. The six values are above this value, but seventh value is less than this value. However the
condition of Col.2 of table 2 is to be verified.
The seventh sample is not acceptable according to code but the decision may be left to the
Engineer-in-Charge.
b. Mean value of the group of 4 non over lapping consecutive test results, as per Col. 2 of Table
2 or fck + 0.825 *3.5 i.e. 15+0.825 *3.5 = 17.88 N/mm2 or fck +3 whichever is greater. Mean
of last 4 values is 16.325 N/mm2, less than the above value. Hence the seventh sample is not
acceptable.

ILLUSTRATION OF PREPARATION OF CONTROL CHARTS FOR CEMENT AND

CONCRETE

A. CONTROL CHARTS FOR CONCRETE STRENGTHS

An illustrative set of compressive strength data (hypothetical data) and its further analysis for
incorporation in a typical set of control charts is shown in the enclosed Table A. It is assumed that

168
3 companion specimen samples are made from each homogeneous batch and constitute a “test”.
Thirty such tests are covered in this Table A.

Master Chart

The-axis indicates the chronological order of tests (col. 1 of the Table A). Strengths of the
individual companion specimens constituting a given “test” (Cols.2 to 4) are plotted one above the
other along the ordinate and their mean values (col.5) representing each test are joined to generate
the Chart. Refer Plate 1A.
Moving average strength chart
Each test is averaged with 4 number of previous tests, making a total of 5 and this moving
average, viz average of 5 consecutive tests (col 6) is plotted. Refer Plate 2A.
Range Chart
The range between the maximum 5 consecutive tests as shown in Col 7 is also plotted. This
chart monitors the overall batch to batch variation of production Refer Plate2A.
The target average strength and control limits can be estimated depending on the percentage of test
values permitted to fall below the specified or “characteristic” strength fsp in terms of the standard
deviation δ (or coefficient of variation Cv) corresponding to the degree of control aimed at. The
target average strength (TAV) is worked out as.
Fsp + 0.84 δ for mass concrete
And Fsp + 1.65 for structural concrete conforming to IS: 456
The standard deviation is what is assumed for mix design. For mass concrete coefficient of
variation Cv is assumed as 15% and the target average strength is 160+0.84 δ.
Then δ/(160+0.84 δ) = Cv 15%
Solving, δ = 27.5 kg/cm2
So, target av. Strength = 150 + 0.84 δ
= 160 + 0.84 * 2.75
= 182 Kg/cm2
Upper warning limit (UWL) = 183 + 0.84 δ(TAV + 0.84 δ)
206 Kg/cm2
Lower warning limit (LWL) = 160 Kg/cm2 (viz. fsp)
Upper Action Limit (UAL) = 183 + 3 *27.5
= 265 Kg/cm2
Lower Action Limit (LAL) = 183 - 3 δ
= 101 Kg/cm2

169
 Lower Warning Limit = 183 + 0.84 * 27.5/√5
The control charts, incorporating these limits are exhibited in Plates 1A, 2A.
The lower action limit (LAL) shall in no case, be lower than the absolute minimum strength
wherever specified IS: 456 -1978 specifies on over riding absolute minimum of 0.8 times the
characteristic concrete strength.
Target average range = d*6 =2.326*27.5=64
This is depicted in Control Chart 3A.
B. CONTROL CHARTS FOR CEMENT STRENGTHS
An illustrative set of strengths data and its analysis for incorporation in a typical set of control
charts is shown in the enclosed Table B. Thirty-One tests (each consisting of 3 companion
specimens) are covered in the Table B. The master chart, moving average strength chart and the
range chart (range between the maximum and minimum 5 consecutive tests) are depicted in Plates
1B, 2B and 3B respectively.
Target Average Strength = 45 Kg/cm2
Coefficient of variation (Cv) = 8%
So, Standard deviation (δ) = 45 * 8% = 36 Kg/cm2

The Upper and lower warning

limits are set as = 450 ± 1.65 * δ
Upper warning limit (UWL) = 450 +1.65 *36
509 Kg/cm2
Lower warning limit (LWL) = 450 – 1.65 *36
391 Kg/cm2
The upper and lower limits are
set as = 450 ± 3*δ
Upper Action Limit (UAL) = 450+ 3*36
558 Kg/cm2
Lower Action Limit (LAL) = 450-3*36
342 Kg/cm2
The lower action limit (LAL) should in no case to lower than the minimum specified strengths in
IS specifications IS:269 or IS:1469 (330 Kg/cm2 at 28 days).
The control charts incorporating these limits are exhibited in Plates 1B and 2B.
Target Average Range = d * δ

170
d = coefficient depending upon the no. of tests considered for obtaining the range and for 5
consecutive tests, d = 2.326
So, Target Average Range = 2.326 * 36 = 84 Kg/cm2
The control chart of cement test result ranges (between maximum and minimum of consecutive
tests), depicting the mean sample range (84 Kg/cm2) as well, is shown in Plate 3B.

171
 TABLE – A
ILLUSTRATIVE DATA AND ITS ANALYSIS FOR SETTING UP CONTROL CHARTS
OF CONCRETE STRENGTHS (Mass Concrete) @nvv

Location Strength of Individual Test value Moving Range bet.

on X-axis Companion Specimens “T” Avg. of Max & (X̅ -X)2
of chart S. (Mean of a, “T” min 5
No./Date b& c) (Five consecutiv =( X̅ -
of Sample (X) consecut e tests Col 5)2
(Kg/cm2 ive tests)
a b c
Compressive strength at 28
days (Kg/cm2)
1 2 3 4 5 6 7 8
1 191 193 195 193 - - 1.96
2 181 185 186 184 - - 57.76
3 183 188 187 186 - - 31.36
4 198 195 192 195 - - 11.56
5 166 173 171 170 185.6 25 466.56
6 177 176 172 175 182.0 25 275.56
7 150 146 148 148 174.8 47 1900.96
8 187 191 192 190 175.6 47 2.56
9 214 211 211 212 179.0 64 416.16
10 212 217 216 215 188.0 67 547.56
11 232 231 227 230 199.0 82 1474.56
12 218 218 224 220 213.4 40 806.56
13 192 194 190 192 213.8 38 1.60
14 181 182 177 180 207.4 50 134.56
15 190 192 194 192 202.8 50 1.60
16 198 199 194 197 196.2 40 29.16
17 197 197 200 198 191.8 18 40.96
18 180 183 183 182 189.8 18 92.16
19 190 191 195 192 192.2 16 1.60
20 197 198 190 195 192.8 16 11.56
21 187 189 19 190 191.4 16 2.56
22 197 188 191 192 190.2 13 1.60
23 240 244 236 240 201.8 50 2342.56
24 208 208 214 210 205.4 50 338.56
25 155 150 151 152 196.8 88 1568.16
26 152 147 145 148 188.4 92 1900.96
27 168 166 161 165 183.0 92 707.56
28 193 198 200 197 174.4 62 29.16
29 222 214 215 217 175.8 69 237.16
30 187 188 195 190 183.4 69 2.56

172
STATISTICAL ANALYSIS

N (No. of samples) = 30
X̅ Av. Strength) = 191.6 (Av. of Column 5 viz. 5747/30)
Sd (δ) = 21.52 kg/cm2 Total of column 8 = 13437.16
COV (Cv) = 11.23% (X̅ -X)2 =
Percentage of sample = 90% SD (δ) = √13437.16 / N-1

Passing (viz. Comp. Strength more than fsp of 160 x kg/cm2) = 21.52 kg/cm2

NOTE: The data listed are hypothetical and in arbitrary units and are meant only to illustrate
their analysis for incorporation in control charts.

* Conc. Grade A150 S160

* Cement level 170 kg/m3
* Specified strength 160 kg/cm2 (fsp)

173
 TABLE – B
ILLUSTRATIVE DATA AND ITS ANALYSIS FOR SETTING UP CONTROL CHARTS
OF CEMENT STRENGTHS
Minimum 28 days strength as per IS: 269 = 330 kg/cm2

Location on
Average Moving Range bet.
X-axis of
Compressive Strength @ 28 days three of 4, 5 Avg. of 5 Max & min 5
chart S.
individual specimens and 6 consecutive consecutive
No./Date of
test results test results
Sample
1 2 3 4 5 6 7
1 500 490 495 495 - -
2 450 430 425 435 - -
3 500 480 490 490 - -
4 550 555 545 550 - -
5 415 430 415 420 478 130
6 430 430 430 430 465 130
7 400 390 395 395 457 155
8 405 425 445 425 444 155
9 440 445 450 445 423 50
10 465 435 435 445 428 50
11 445 435 440 440 430 50
12 450 410 430 430 437 20
13 505 495 500 500 452 70
14 500 495 490 490 462 70
15 465 450 450 455 464 70
16 445 465 455 455 467 70
17 465 490 485 480 477 45
18 430 445 445 440 465 55
19 445 455 465 455 457 40
20 410 430 420 420 450 60
21 490 510 485 495 458 75
22 450 450 465 455 453 75
23 450 435 450 445 454 75
24 470 460 465 465 456 75
25 475 470 465 470 466 50
26 450 465 465 460 459 25
27 460 450 440 450 458 25
28 450 450 450 450 459 20
29 470 470 470 470 460 20
30 490 490 490 490 464 40
31 470 475 480 475 467 40

STATISTICAL ANALYSIS

N = 31 Target Av. Range: 84 kg/cm2

X̅ = 459 (Av. of Column 5 viz. 14220/31)
Sd (δ) = 30.49
Cov (Cv) = 6.65%

174
 2.8 COMPILATION OF QUALITY CONTROL DATA

Quality Control of data refers to the application of methods or process that determine
whether data meet overall quality goods and defined quality criteria for individual values
and Quality control data shall be compiled on a continuing basis and reports prepared in a
booklet form at regular intervals. These reports should include the following:
1. Brief report of the project for which the data is compiled.
2. Index plan.
3. Geologists report depending upon the nature of the project.
4. Note on foundation treatment, grouting pattern if suggested.
5. Nature of input materials like soil, cement, aggregates, steel and their source of supply.
6. Test reports on input materials and acceptance criteria as laid on in IS Codes.
7. Design of concrete mixes.
8. Summary of records and reports on grouting as specified in I.S. 6066-1984 and other IS
Codes.
9. Test reports on concrete like slump, compressive strength etc.
10. Control charts for cement and cement concrete i.e. Master charts, moving average
strength and range chart etc.
11. Statement showing the deployment of machinery.
12. Statement showing the quantity of concrete and earth work executed and number of cube
tests conducted.

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 2.9 MANUFACTURED SAND

2.9.1 MANUFACTURED SAND:

Today Indian Standards are copiously used for ensuring quality of construction of buildings
and other structures, which are now-a-days largely dependent on concrete constructions. Bureau of
Indian Standards, the National Standards Body of the country, considering the scarcity of sand and
coarse aggregates from natural sources, has evolved number of alternatives which are ultimately
aimed at conservation of natural resources apart from promoting use of various waste materials
without compromising in quality.

The IS 383-2016 code of aggregates defines the types of fine aggregates as

1. Natural Sand
2. Crushed Gravel Sand
3. Crushed Stone Sand
The IS code clearly specifies that the crushed gravel sand and crushed stone sand can be
used in concrete. The size of the crushed gravel sand and crushed stone sand shall be within the
range of 2.36 mm to 4.75 mm.

Before using the crushed gravel sand and crushed stone sand, it has to be dust free and for
this air blowing and water washing shall be adopted. The texture of the crushed gravel sand and
crushed stone sand shall be angular in nature but not flaky.

If the crushed gravel sand and crushed stone sand are to be used in filters for Earthwork
Embankment and canal lining, separate model studies have to be experimented.

The Government have encouraged the usage of Manufactured Sand in ongoing Government
works and recognized the manufactured sand production units as an industry and gave certain
subsidy. To this extent, the Government have issued G.O. Ms. No. 3 Dt.08.01.2015.

Note: Usage of Manufactured shall be referred to the Chief Engineer, Central Designs
Organization for approval and adoption.

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 2.10 GEOSYNTHETICS
The construction of embankments on soft soils can be a challenging task. In this context, the
use of geo-synthetics to improve embankment stability is one of the most effectives and well-tried
forms of the soil reinforcement technique.
Geosynthetics can be effectively used to:
1) Reduce soft soils displacements due to low bearing capacity of soft soils

2) Prevent overall failure of the embankment and soft foundation soil;

3) Prevent sliding failure along the geosynthetics surface.

The efficiency of geosynthetics as reinforcements of embankments on soft soils can be

visualized by the following figures.

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 In case of limited reinforcement effect, the so called basal reinforced pile embankment can
be used. Prefabricated piles or improved soil piles can be employed.

Note: Usage of Geo synthetics shall be referred to the Chief Engineer, Central Designs
Organization for approval and adoption.

Geosynthetic is defined as a planar product manufactured from a polymeric material which

are used with soil, rock, or other geotechnical-related material to improve its performance. Synthetic
materials in the form of strong flexible sheets either woven or nonwoven, permeable or water tight,
2- dimensional or 3- dimensional have been used for several years to improve soil quality and
performance in different facets of geotechnical engineering, e.g. base and sub base stabilization,
reinforcement, drainage, protection of slopes and embankments.

Geosynthetics are usually sheet materials supplied in roll form and they are used in many
geotechnical applications. There are five key categories - geotextiles (sub divided into woven and
non-woven) and related products (materials such as erosion mats & cuspates), geogrids, geocell,
geomembranes, geocomposite etc., have been progressively developed for various applications. A
common generic name ‘Geosynthetics’ is being used to refer the different materials mentioned
above.

Classification of geosynthetics: Geosynthetics can be classified in many ways based on

manufacturing process, materials used or function. The classification is based on the spatial aspects
of the geosynthetic material. For example, one dimensional material will have only one spatial

178
character as length compared to other dimensions (ropes, straps and cables). Two dimensional
materials will have only two spatial characteristics either length or width or height (Geotextiles,
Geogrids, Geomembranes and Geocomposites), whereas three dimensional materials will possess
the spatial characteristics in all three dimensions i.e. length, width and height (geocell, geomats,
geonets, geospacers and three dimensional geogrids).

1. Geotextile: Any permeable textile (natural or synthetic) used with foundation, soil, rock,
earth, or any other geotechnical engineering-related material as an integral part of a human-
made project, structure, or system. The geotextiles are generally classified by the
manufacturing process and are often separated into two sub-categories, namely, woven and
non-woven. Another type of geotextile includes (i) Knitted geotextiles and (ii) Composite
geotextiles
a) Woven Geotextile: A planar textile structure produced by interlacing two or more sets
of elements, such as yarns, fibres, roving, or filaments, where the elements pass each
other, usually at right angles and one set of elements are parallel to the fabric axis.
b) Non Woven Geotextile: For geotextiles, a planar and essentially random textile structure
produced by bonding. interlocking of fibers, or both, accomplished by mechanical,
chemical, thermal, or solvent means, and combinations thereof.
c) Knitted Geotextile: consists of a single strand systematically intertwined with itself and
is manufactured with a knitting machine, instead of a weaving loom.
d) Composite Geotextile: (Multi-layered geotextiles) are manufactured by combining
layers of different types of geotextiles. The components can be combined by needling,
stitching, chemical bonding or heat bonding.

Geogrid: A deformed or nondeformed netlike polymeric material used with foundation, soil, rock,
earth, or any other geotechnical engineering- related material as an integral part of the human- made
project structure or system.
Geogrids are polymers formed into a very open, grid like configuration, i.e., they have
apertures between individual ribs in the transverse and longitudinal directions. Geogrids are mainly
made from polymeric materials, typically polypropylene (PP), high density polyethylene (HDPE)
and polyester (PET).
Geogrids can be classified according to
(a) manufacturing process (woven, knitted, bonded, welded, extruded),
(b) directional behavior (uniaxial, biaxial, etc.),
(c) bonding between ribs and

179
 (d) Polymer (polypropylene, polyester, PVC etc).
Biaxial geogrids have significant strength in both the machine and cross machine directions.

Geomembrane: An essentially impermeable membrane (liner or barrier) used with foundation, soil,
rock, earth, or any other geotechnical engineering-related materia1 as an integral part of human-
made project, structure, or system, used to control fluid migration.
These are made from relatively thin continuous polymeric sheets, but they can also be made
from the impregnation of geotextiles with bitumen, polymer sprays or as multilayered bitumen
geocomposites. Continuous polymer sheet geomembranes are by far the most common.

Geocomposite: A manufactured material using geotextiles, geogrids, and/or geomembranes in

laminated or composite form.

Geocell: Geocell (also known as Cellular Confinement System) is a three- dimensional

honeycombed cellular structure that form a confinement system when in- filled with compacted soil
or aggregate, thereby forming a mattress for increased bearing capacity and maneuverability on
loose or compressible subsoils.
Extruded from polymeric materials such as HDPE, into strips welded together ultrasonically
in series or in continuous process capable to create the cells without any subsequent welding, the
geocell structures, the strips are expanded to form the stiff (and typically textured and perforated)
walls of a flexible 3D cellular mattress. The material is UV stabilized with carbon black.

Functions of Geosynthetics:
In a given application, a geosynthetic can perform one or several functions to improve the
mechanical and/or hydraulic behavior of the structure in which it is incorporated. The basic
functions performed by a geosynthetic are as follows:
1. Separation
2. Reinforcement
3. Filtration
4. Drainage
5. Moisture Barrier
6. Erosion Control
Each of these functions can be defined in terms of the role they fulfil in the installation.

Definitions and description of each of these functions are explained below.

180
Separation: Preventing intermixing of soil types or soil/aggregate to maintain the integrity of each
material yet still allow the free passage of liquids/gases. Commonly used in between sub
base/subgrade and around drainage materials. This function is rarely used in isolation; it is normally
combined with one or more of the other functions, filtration and reinforcement being most usual.

One of the only pure uses of a geosynthetic as a separator is at the base of fill for a temporary
haul road, but even there, in most situations the geotextile also acts as reinforcement. The design of
the geosynthetic will be based on a tensile strength requirement, the puncture resistance (CBR or
Cone Drop resistance) and durability tests to determine the survivability in the service environment.

Reinforcement: Providing additional strength to soils to enable steep slopes and soil structures to
be constructed, and allow construction over weak and variable soils. Geosynthetics used as
reinforcement are normally high strength woven geotextiles or Geogrids. The reinforcement
products are subject to more analytical design than for any other function. There are numerous
programs now available to allow engineers to design the reinforcements for over-steep slopes, basal
reinforcements for embankments on soft ground, and reinforcements to voids and piled foundations.
The specification for reinforcements may include both the short term tensile strength and the creep
limited tensile strength depending on the nature and the length of time the geotextile will be under
load.

Filtration: Restraining soil particles are subject to hydraulic forces whilst allowing the passage of
liquids/gases. This function is often partnered with separation e.g. in coastal defence applications
or wrapped drains Geosynthetics are widely used for filtration in road works and railway
constructions as well as coastal protection. The characteristic opening size of Geosynthetics is
designed to retain particles while allowing free movement of water, making it possible to separate
two layers during intense hydraulic activity. Migration of layers, which would reduce the load-
bearing capacity of the construction, is thereby avoided and, at the same time, water flow is
maintained with minimum pressure loss. The tensile strength, puncture resistance and elongation
properties of the geosynthetic have to be sufficient not only to fulfil the requirements of a filtrator
but also to resist damage during installation. This is a well-established function, where there are
economic advantages, as geosynthetics act as a direct replacement for selected, graded granular
filters. Drainage geosynthetics are commonplace in highway drainage systems, beneath revetments,
sea defence groynes, sludge dewatering systems and can be used in the drainage systems of dams.
The application of geotextiles in dams has taken some time to be accepted by engineers responsible
for dam safety because the consequences of a failure of the drainage / filter systems in a dam

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structure need to be avoided. The design of filters is by relating the laboratory measured effective
opening size (usually the O90 or O95), the method of manufacture of the geotextile (woven or non-
woven) to one or more of the soil grading characteristics (d10, d50 or d90). Checks are required to
ensure that the geotextile acts:

• As a filter - to stop the loss of fine particles from the protected soil.
• To allow water to pass through at a rate not less than the permeability of the soil allows water to
reach the surface of the geotextile.
• Such that the fine soil particles do not clog the apertures in the geotextile – clogging needs to be
avoided when using thick non- woven geotextiles.

Drainage: Drainage is collecting and transporting of precipitation, ground water, and/or other fluids
in the plane of a geosynthetic material. A suitable permeable geosynthetic material provides a
filtration function which serves the same role in soil structures as the various gradation of granular
material.

Moisture Barrier: The barrier function refers to the prevention or limits the migration of fluid across
the plane of the geosynthetic material. The most frequent use of this function is in landfills where
impermeable linings prevent contamination of surrounding soils. They are used to prevent the
escape of liquids from containments or to prevent or reduce the flow of liquids through soils or
other parts of construction works.

Erosion Control: Use of a geosynthetic material is to prevent or limit soil or other particle
movements at the surface of a slope due to water run-off and/or wind forces. In addition to the
primary function, Geosynthetics usually perform one or more secondary functions. The primary and
secondary functions of geosynthetic make up the total contribution material in better way to a
particular application. It is important to consider both the primary and secondary functions in the
design computations and specifications.

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 Primary Functions of Geosynthetics

Primary Functions of Geosynthetics

Type of
Impermeable Erosion
Geosynthetic Separation Reinforcement Filtration Drainage
Barrier Control
Geotextile     
Geogrid  
Geomembrane  
Geocell  
Geocomposite      
Geonet  
Geospacer   
Geomat  
Geotube  
Geobag 
Paving Fabric 
Paving Grid 

Note: The given matrix of primary functions is indicative only; each product can have multiple
functions as per site conditions.

Use and selection of geosynthetics has to be analyzed based on site conditions,

applicabilityand project specific requirements with judgement of Engineer in Charge. However,
before actually begin with design, a designer must give due consideration to “Engineering” and
“Economic” factors involved in design.

2.10.1 PROPERTIES AND TEST METHODS FOR DIFFERENT GEOSYNTHETIC

MATERIALS

Geosynthetic Materials shall be Tested and Certified in the following manner:

• The manufacturer shall have International Organization for Standardization (ISO) or Conformite
Europeenne (CE) certification for manufacturing process and quality control.

183
• The manufacturer shall provide manufacturer’s test certificate for every lot supplied from the
factory.
• The supplier shall provide third party test reports from an independent laboratory with valid
accreditation for all the test values in Manufacturer’s test certificate.
Geosynthetics shall be tested in accordance with tests prescribed by relevant Bureau of Indian
Standards (BIS), International Organization for Standardization (ISO), American Society for
Testing and Materials (ASTM), European Standards (EN) or British Standard (BS) shall be
conducted.

Geotextile:
This gives an insight into various properties of geotextiles and test methods in use or currently
favoured for testing of geotextiles as per existing worldwide standards. This section has been
subdivided into following three major categories:

• Physical properties
• Mechanical properties
• Hydraulic properties
Physical properties: The properties, discussed in the sub section, refer to fabric in its manufactured
or as received condition. Physical properties are considered to be index properties of geotextiles.

a) Specific gravity
b) Mass per unit area and
c) Thickness.

Mechanical properties: The mechanical properties to be discussed here indicate the geotextiles
resistance to tensile stresses mobilized under applied loads and/or installation conditions. The index
tests such as
a) wide width tensile strength,
b) grab strength,
c) puncture strength and
d) sewn seam strength

The above tests are used for determining the mechanical properties of the geotextiles.

Hydraulic properties: Filter system flow capacity or flow rate, q is the quantity of water, which will
pass through the system in a given period of time. Flow capacity is usually expressed in cm3
/sec or cm3 /sec/ m2. Properties of both the soil and geotextile influence the hydraulic characteristics

184
of the soil/ geotextile system. Two important properties are soil permeability and geotextile
permittivity. Other properties are listed below

Soil/Geotextile Filter System Properties

Soil Geotextile
Permeability Permittivity
Grain size distribution Apparent opening size
Plasticity Per cent open area
Dispersivity Structure
Compaction and confinement Durability

Geotextile Properties and Testing Methods

Property Test Method

Specific gravity ASTM D792 or ASTM D1505
Mass per unit area IS:14716, ISO 9864, ASTM D5261
Thickness IS:13162 (Part 3), ISO 9863, ASTM D5199

Tensile strength
IS:13325, ISO 10319, ASTM D4595
i. Grab strength test
IS:16342, ISO 13934, ASTM D4632, ASTM
ii. Narrow strip test
D751
IS:13162 (Part 4), IS:16078 (For CBR Puncture
Puncture strength
strength), ISO 12236, ASTM D6241
Sewn seam strength ASTM D4884
Apparent Opening Size (AOS)/Characteristic
IS:14294, ISO 12956, ASTM D4751
Opening Size (COS)
Permittivity IS:14324, ISO 11058, ASTM D4491
Clogging potential IS:16389
i. Gradient ratio test ASTM D5101
ii. Hydraulic conductivity ratio test ASTM D5567

185
ANNEXURES

186
 ANNEXURE- I

In-situ Permeability by Japanese Method:

1. Scrap all top loose materials at the desired area for an extent of 6’ x 6’.
2. Make a trench of bottom dimensions of 4’ x 2’ and 1’9” deep with side slopes 1:1, the
trench may be excavated with vertical sides if the soil permits.
3. Have a cane calibrated in 1/10 gallons from which water cane be fed into the pond.
4. Fill up trench with water to a depth of 3” from the top and go on feeding water into the
trench from the reservoir so the water level is maintained constant at a depth of 3” from
the top surface.
5. Record the water intake every hour.
6. The experiment should be continued till the intake readings are steady say for a period
of 4 hours (atleast).
7. Extend the pit to the 4’ x 4’ at the bottom cutting an extra width of 1 feet on either of
the shorter side of the trench.
8. Feed the trench with water as in the previous case maintain the water level in the pit 3”
from the top.
9. Measure the intake every one hour for a period of 2 hours more till the intake is constant.
10. Determine the extra amount of water require to maintain the level in the pit after it has
been extended.
If the extra amount of water is 1/100 gallon per hour, permeability is 1 ft/year. If the
extra amount of water is 1/100 gallon per hour, permeability is 10ft/year. If the extra
amount of water is 1 gallon per hour, is permeability is 100 ft/year.

In-situ Permeability Test by Japanese Method

Location of Test: Elevation:
Date of Test:
First Stage
Size of Pit: 4’ x 2’ x 1’9”
Starting Time Ending Time Intake in litres

187
Second Stage
Size of Pit: 4’ x 4’ x 1’9”
Starting Time Ending Time Intake in litres

Steady Volume of water (a) in lit/hr = Steady Volume of water (b) in lit/hr =
Extra amount of water (a-b) in lit/hr = Extra amount of water (a-b) in gallon/hr =
Unit Conversion 1 gallon/ hr = 100 ft/ year 1 gallon = 4.536 lakh

Calculating for ft/ year =

Calculating for cm/ sec =

Remarks:

Signature of the agency Construction Staff Quality Control Staff

188
ANNEXURES –II

189
 ANNEXURE- III

ILLUSTRATIVE SKETCH SHOWING TREATMENT OF CANAL PRISM IN

EXPANSIVE SOILS WITH CNS MATERIAL

190
ILLUSTRATIVE SKETCH SHOWING COMPACTION OF CNS SOILS IN
DISTRIBUTORIES

191
 ANNEXURE-IV

DATA OF THE CORES TAKEN FROM IN-SITU CONCRETE CANAL LINING

Name of Canal Grade of Concrete Mix

Reach Slump

Name of the Contractor W/C ratio

Indicated Compressive Type of Alkali

Chainage & Thickness of Density of
compressive strength Curing Reactivity
S. Location of lining Density of standard specimen Water
strength of after Water or test results of Remarks
No. Test Core exhibited by core gm/cc prepared in absorption%
core correction curing representative
bed/slope core (cm) Laboratory
Kg/cm2 Kg/cm2 compound sample
1 2 3 4 5 6 7 8 9 10 11

1.

2.

3.

192
 ANNEXURES –V

PLATES

PLATE- 1 A PLATE- 1 B

CONTROL CHART FOR 28 DAYS STRENGTH OF MASS

CONCRETE INDIVIDUAL TESTS AVERAGE COMPRESSIVE STRENGTH @ 28 DAYS

193
 PLATE 2A PLATE 2B

CONTROL CHART FOR 28 DAYS STRENGTH OF MASS

CONCRETE- MOVING AVERAGE CO EFFICIENT OF VARIATION

194
RANGE BETWEEN MAX. & MIN. OF 5 CONSECUTIVE RESULTS

STANDARD DEVIATION CHART

195
 ANNEXURE-VI

IMPORTANT CIRCULAR's, GO's, MEMO's – QUALITY ASPECTS

S. Reference Relate Gist Rem

N d to arks
o
1 Lr Quality Format for issuing of Quality control certificates along
No.ENC(I)/DCE Contro with checkslip
1 /OTMP/AEE5, l
Dt:27.04.2009 Certifi
2 Lr cate Guidelines for Quality control checks and issue of
No.ENC(I)/DCE Format Quality control certificates for Mission kakatiya works
1 s
/OT3/AEE9/QC,
Dt:29.05.2015
3 Memo O&M Quality control Aspects: Quality control verification
No.ENC(O&M)/ works and certification shall continue as per the existing
EE-1/DEE/ of procedures with a provision to get the works inspected
AEE/2021/232, Emerg during their execution for emergency and restoration
Dt:22.05.2021 ency works instead of conducting inspection after completion
and of works so that atleast one inspection is ensured even
deferre for emergency works. The quality certificate for
d mechanical works should be given by EE of
mainte Mechanical circle.
nance-
Genera
l
guideli
nes and
instruct
ions
4 Circular O&M Nature Sancti Place Nature of Valu QC
No.ENC(O&M) works - of oning ment work e of certific
&QC Issue work Author Regist work ates to
/EEIII/DEE/ of ity er to be
AEE/QC Placem be issued
check/2021/507, ent issued by
Dt:03.08.2021 register by
and Memo & QC O&M EE, EE,Q Civil upto DEE,
No.ENC(O&M) certific /Emer Constr C works- 2.00 QC
&QC ates- gency uction FDR lakhs
/EEIII/DEE/ Modifi works CE/SE SE,QC temporary Mor EE,Q
AEE/QC ed constr /O&M e C
check/2021/581, instruct uction works/Em than
Dt:21.08.2021 ions ergency 2.00
works lakhs
FDR EE, EE,Q Civil upto AEE/
Works Constr C works- 1.00 AE,
uction FDR lakhs QC
Permanen 1.00 DEE,
t works lakh QC
to
10.0
0
lakhs

196
 inclu
ding
CE/SE SE,QC Mor EE,Q
constr e C
uction than
10
lakhs
Mecha CE/SE SE Mechanic No EE
nical /EE (Mech al & limit
(Mech
works anical Electrical anical
) Hyd works )Hyd
5 Circular Memo Issue References of 1. Requisition letter of EE (construction).
No.CE/ of 2. Letter of EE,QC to the concerned Dy.EE, QC
QC/HYD /DEE Quality 3. Letter of Dy.EE,QC to the EE,QC while issuing the
/AEE2/2022/335, control QCC.
Dt:30.08.2022 certific
6 Minutes of ates 1. Value of work should be included in the Quality
Review meeting Control Certificate. 2. The field evaluation sheet shall
by CE/QC,Hyd invariably enclosed for each and every QCC.
on 13.09.2022
Endt No.
CE/QC/HYD/DE
E/AEE1/388,
Dt:24.09.2022
7 Memo No.CE/ Instruc 1.Approved drawings are duly approved by the
QC/HYD /DEE tions competent authority before commencement of work.
/AEE1/CD/827, for 2. Obtain soil test reports and design mix from the
Dt:14.03.2023 Check concerned Quality control Laboratories/NABL
Memo No.CE/ dams accredited Laboratory.
8
QC/HYD /DEE 3. Obtain necessary approvals(i.e., Inspection
/AEE2/CD/2023/ reports/Approved drawings) from the competent
222, authorities for any deviations.
Dt:17.06.2023 4. To maintain the Placement register, Material test,
Slump & temperature, cube strength,
Reinforcement,FDD,Benchmark,Site order, LF
book,OK cards and shall be made available at site.
5. The CC cores shall be extracted as per the frequency
and get tested in ISO certified labs.
6. SBC of soil shall be assessed to ensure the same
within the permissible limits 7. The bottom
levels of all the components of the structure of
checkdam shall be verified by both QC and
construction staff and posted in the LF book.
9 Memo No.CE/ instruct 1. It is instructed to all the field staff, to inspect all the
QC/HYD /DEE ions to works regularly.
/AEE2/27, be 2. must be specific while reporting the
Dt:15.04.2023 follow chainages/Levels/structure details etc., 3. advised to
ed by check all the linear measurements thoroughly before
field laying of RCC.4. make necessary arrangements to
staff extract CC cores as per Agreement/IS codes.
10 Circular Instruc 1. QC shall be verifying the works at random for
No.ENC(O&M tions which all the list of works should be furnished to
)/EE-1/DEE/ for them. 2. Quality checks must be performed by both
AEE1/2023/FD FDR construction and quality control staff covering all
R/935, 2023- the works. 3.Issue of placement register, Quality
Dt:03.08.2023 24 control verification and certification shall continue

197
 as per the procedures in vogue.The QCC must be
issued/returned within a week after the request
received from the construction division.

11 Memo No.CE/ 1. All the Executive Engineers are instructed to

QC/HYD /DEE Assure the Quantities/Measurements recorded.
/AEE2/2024/10 2. All the Executive Engineers are instructed to
42, verify all the QC records along with the bill.
Dt:13.03.2024 3.Evaluation Certificate must be maintained for
office record
12 Memo Canal Guidelines for verification of quality control
No.31443/Refo linin aspects of canal lining works
rms/A1/2007 Works
Dt:28-05-2013

198
 ANNEXURE VII
OK CARDS FORMATS
O. K. CARD FOR EARTH WORK EMBANKMENT

Quality
S. Contr Construction
Description Control Remarks
No. actor staff
Staff
1. Date
2. Name and location of borrow area
Prerequisite: Benching, stripping of
base whether key trench is made and
base watering is done
3. Location of work from Km _____ to
Km _____
4. Elevation (R.L.,)
5. Surface preparation, whether as per
specification.
6. Type of roller used.
7. Location of test at Km.
8. Thickness of loose layer.
9. Initial moisture content
10. Removal of oversize material,
vegetation and debris etc.
11. Top level after compaction

12. Wet density

13. Moisture content in rolled fill
14. Dry density
15. Laboratory OMC and MDD
16. Compaction efficiency
17. Embankment of instruments devices
(in case of earth dam)
18. Methodology of addition of moisture
(whether through spray from
sprinkler tanker)
19. Manual compaction, if any
20. Layer passed
21. Any other remarks

Signature of Site in Signature of Construction Signature of Quality Control Staff

Charge (Contractor Staff
Representative) A. E. E./DEE/EE A. E. E./DEE/EE

199
 O. K. CARD FOR SUB GRADE PREPARATION

Quality
S. Constructi
Description Contractor Control Remarks
No. on staff
Staff
1. Date
2. Location
3. Whether sub-grade is prepared
as per specification in case of
a) ROCK – (Over excavation)
b) Swelling soils (Treatment
with CNS soils)
c) Over excavation in soils
4. Whether the profile of canal
section is prepared to model
section.
5. Whether porous plugs are casted
as per specification.
6. Whether the work of laying the
filter media is carried out as per
approved drawing in case of
a) Porous Plugs
b) Longitudinal and transverse
drains
7. Flap valves placed as per
drawing
8. Whether sub-grade is wetted to
150 mm depth as per
specification.
9. Compaction of sub-grade
10. Methodology of compaction.
11. Methodology of wetting of sub-
grade
12. Any other remarks

O. K. CARD FOR CAST – INSITU CONCRETE LINING

Signature of Site In Signature of Construction Signature of Quality Control Staff
Charge (Contractor Staff
Representative)
A. E. E./DEE/EE A. E. E./DEE/EE

200
 Quality
Constructi
S. No. Description Contractor Control Remarks
on staff
@Nv

Staff
1. Date
2. Location from Km _____ to
_____ Km _____ bed side
slope L/R
3. Proportion of the mix
4. Materials
a) Coarse aggregate
under/over size 40mm, 20mm
& 10mm
b) Fine aggregate F.M. of sand
c) Cement make/Date of
Manufacture
d) Admixtures make/date of
mfr. And % used.
5. Method of concrete mix
a) Mix by Vol./Wt.
b) Batching plant by Vol./ Wt.
6. Transport
a) By transit mixer
7. Temperature of concrete
specified
8. Temperature of concrete as
placed
9. Slumps
a) At the batching plant
b) At the site of placement
10. Water Cement Ratio
11. Method of consolidation slip/
Mechanical vibrators/screened
vibrator
12. Whether contraction /
Construction Joints are
provided as per approved
drawings
13. Treatment of cold joint/joints
14. Curing: Water curing/curing
compound

201
15. The quantity of curing
compound utilized in liters
16. The reflectance on curing
compound
17. Quantity of concrete laid/cum
and area in Sq mts
18. Whether LDPE/HDPE sheet is
laid
19. No. of C.C. cubes casted
20. Any other remarks

Signature of
Site In Charge Signature of Construction Staff Signature of Quality Control Staff
(Contractor A. E. E./DEE/EE
Representative) A. E. E./DEE/EE

O. K. CARD FOR MASONRY WORK

202
 Quality
Constructi
S. No. Description Contractor Control Remarks
on staff
Staff
1. Date
2. Location of work
a) Component of work (with
Elevation)
3. Specification of work
4. Cleaning of Old Layer
5. Curing of Old Layer
6. Batching of Cement Mortar
7. Materials whether available as
per
a) R.R. Stones
b) C.R. Stones
c) Bond Stones
d) Dressing of stones
e) Sand F.M.
8. Placing of Stone, hearting and
thickness of joints
9. No. of C.M. Samples collected
10. Any other remarks

Signature Signature of Construction Staff Signature of Quality Control Staff

of Site In Charge A. E. E./DEE/EE A. E. E./DEE/EE
(Contractor
Representative)

O. K. CARD FOR STRUCTURAL CONCRETE WORK

203
 Quality
Constructi
S. No. Description Contractor Control Remarks
on staff
Staff
1. Date
2. Grade of Mix
3. Location of work
a) Foundation (with elevation)
b) Super structure (with
elevation)
4. Methodology of preparation of
surface
5. Materials
a) Coarse aggregate under size/
oversize graded analysis.
b) F.M. of sand
c) Cement make/date
d) Water
6. Tools and Plants
a) Form work details of
shuttering should be checked
with dimensions.
b) Mixer
c) Vibrators
7. Batching
8. Temperature of concrete
specified in technical
specifications.
9. Temperature of concrete as
placed
10. SLUMP
a) Design slump
b) At the batching and mixing
plant
c) At the site of placement
11. Method of placing
12. Method of consolidation
13. Water cement ratio
14. Treatment of construction joints
15. Embedments

204
16. Water stopper
17. Concrete finish (Wood float
steel trowel)
18. Quantity of concrete laid
19. No. of CC Cubes cast.
20. Checking of reinforcement
21. Curing arrangements (Water/
Curing Compound)
22. If curing compound is used, total
quantity in Sq. mts.
23. Reflectance
24. Any other remarks

Signature Signature of Construction Signature of Quality Control Staff

Site In Charge Staff
(Contractor A. E. E./DEE/EE A. E. E./DEE/EE
Representative)

O. K. CARD FOR GROUTING

205
 Quality
Constructi
S. No. Description Contractor Control Remarks
on staff
Staff
GENERAL
1. R.L. and area of surface to be
grouted.
2. Classification of the rock strata if
grouting is in rock area
3. Salient features of the strata such
as a fault zone cavities fissures etc.
4. Permeability value of the strata
before grout.
GROUP
5. Pattern of Grout adopted
6. Depth and dia. of the grout hole
7. Pressure adopted for grout
8. Proportion of grouting mix
9. Intake of slurry mortar per unit
area per unit time.
10. Total Quality of Intake
11. Final permeability value of the
strata after grout.
12. Whether the grout strata is OK.

Signature Signature of Construction Staff Signature of Quality Control Staff

of Site in Charge A. E. E./DEE/EE A. E. E./DEE/EE
(Contractor
Representative)

Note: Grouting is the process of placing material into cavities in concrete or masonry
structure for the purpose of increasing load bearing capacity of structures, restoring
monolithic nature of structure. Fine sand is used to avoid segregation.

O. K. CARD FOR SHOTCRETING

206
 Quality
S. No. Description Contractor Constructi Remarks
Control
on staff
Staff
1 Date
Component of Structures

2 Reduced Level and area of

surface to be shotcreted
Methodology of Preparation of
surface

3 a) Green Cutting
b) Sand blasting
c) High pressure water blasting

4 Proportion of the shotcreting mix

5 Materials
a) Coarse aggregate nominal
maximum size 6 mm to 20mm.
b) Fine aggregate F.M. of sand
c) Cement make/Date of
manufacture and % used
d) Admixture like accelerators
Make/Date of manufacture and
% used

6 Method of concrete mix

a) Mix volume/Weight
batch
b) dry mix/wet mix

7 Transport
a) By transit mixer
b) By Mobile self loading/
weight-batching &
mixing and transporting
Temperature of concrete
8
specified
Temperature of concrete as
9
placed

207
10 Slump
a) Design slump
b) i. Slump at the batching
plant.
ii. Slump at the site of
placement.

11 Water Cement Ratio

Curing: Water curing / curing by

12 membrane form of curing

compound.
Quality / Workman Ship of
13 shotcrete

14 Shotcrete layer
a. Layer Number
b. Thickness of Layer
c. Size and diameter of
reinforcement grid

15 Quantity of Shotcrete laid

16 No. of CC Cubes Casted

17 Any other remarks

Signature of Signature of Construction Staff Signature of Quality Control Staff

Site In Charge A. E. E./DEE/EE A. E. E./DEE/EE
(Contractor
Representative)

208
 O. K. CARD TUNNEL EXCAVATION

Quality
Constructi
S. No. Description Contractor Control Remarks
on staff
Staff
GENERAL
1. Date
2. Layout Centre line
3. Scaling of Tunnel Heading
4. Shot-creting (First Layer)
5. Rock bolting Anchoring
6. Drainage holes/Forepoling
7. Geo-technical mapping
8. Wire-mesh placement
9. Shot-creating (second layer)
10. Erection of steel supports
11. Backing/Back-fitting of supports
12. Marking of drill pattern
13. Ventilation
14. Lighting, Monitoring inside Air
15. Drilling blast holes
16. Loading blast holes
17. No. of drill holes. Quantity of
explosives loaded. No. of delays
18. Final O.K. for blast.

Signature Signature of Construction Staff Signature of Quality Control Staff

of Site In-Charge A. E. E./DEE/EE A. E. E./DEE/EE
(Contractor
Representative)

209
S. Construction Quality
Description Contractor Remarks
No. Staff Staff

1 Date of testing

2 Pressure Gauge No. & Serial No’s

3 Pressure Gauge Range (Kg/cm2)

4 Location of fabrication yard

5 Total Length of pipe for Hydro Test

6 Thickness of Pipe

7 Number of Joints

8 Design Test Pressure

9 Applied Test Pressure

10 Pressure Gauge No.1 Reading at Start time

11 Time (Retention Period) from ____to__

12 Pressure Gauge No.1 Reading at Test End

13 Leakage Test Time

14 Leakages observed any

15 Any other Remarks

O. K. CARD FOR HYDRO TESTING (YARD)

Signature Signature of Construction Staff Signature of Quality Control Staff

of Site In-Charge A. E. E./DEE/EE A. E. E./DEE/EE
(Contractor
Representative)

210
 O. K. CARD FOR HYDRO TESTING (FIELD)

S. Contracto Construction Quality

Description Remarks
No. r Staff Staff

1 Date of testing

2 Pressure Gauge No. & Serial No’s

3 Pressure Gauge Range(Kg/cm2)

4 Location of Pipe Line from ____to____

5 Total Length of Hydro Test

6 Thickness of Pipe

7 Row No.

8 Number of Joints

9 Elevation at Stating Point

10 Elevation at End Point

11 Design Test Pressure

12 Applied Test Pressure

13 Pressure Gauge No.1 Reading at Start time

14 Pressure Gauge No.2 Reading at Start time

15 Time (Retention Period) from ____to__

16 Pressure Gauge No.1 Reading at Test End

17 Pressure Gauge No.2 Reading at Test End

18 Any other Remarks

Signature Signature of Construction Staff Signature of Quality Control Staff

of Site In-Charge (A. E. E./DEE/EE) (A. E. E./DEE/EE)
(Contractor
Representative)

211
 O. K. CARD FOR ULTRA SONIC TESTING (UT)

S. Construction Quality
Description Contractor Remarks
No. Staff @Nv
Staff

1 Date of testing

2 Equipment Model No.

3 Frequency of Equipment

4 Thickness & Diameter of Pipe

5 Coup-lent

6 Type of Weld

7 Prob Angle

8 Test Range

9 Calibration Block

10 Location of Pipe Line km __ to km ___

11 Total Length of UT

12 Row No.

13 Pipe No’s & Joint No.

Name & Date of manufacturing of

14
Electrode used

15 Type of Electrode used

16 Diameter of Electrode used

17 Position of the Defect

18 Evaluation

a. Defect Type

b. Length of Defect

c. Depth of Defect

19 Result

Signature
of Site In-Charge Signature of Construction Staff with Signature of Quality Control Staff with
(Contractor (A. E. E./DEE/EE) (A. E. E./DEE/EE)
Representative)

212
 O. K. CARD FOR RADIOGRAPHY

S. Construction Quality
Description Contractor Remarks
No. Staff
@Nv
Staff

1 Date of testing

2 Equipment Model No.

3 Capacity of Equipment

4 Source

5 Package Type

6 Radiography Technique

7 Film Used

8 Film Dimensions

10 Thickness & Diameter of Pipe

Location of Pipe Line from ____ to

11
____

12 Pipe No.

13 Type of Weld Joint

Position of Film
14
(A-B) (B-C) (C-D) (D-A) (LS1) (LS2)

Exposed Time From ________ to

15
_____

16 Any Remarks

Signature Signature of Construction Staff Signature of Quality Control Staff

of Site In-Charge (A. E. E./DEE/EE) (A. E. E./DEE/EE)
(Contractor
Representative)

213
 O. K. CARD FOR LIQUID EPOXY COATING IN PRESSURE MAINS
(Primer)
S. Construction Quality
Description Contractor Remarks
No. Staff
@Nv
Staff

1. Date of Primer Coating

2. Fabrication yard Number

3. Pipe Number

5. Sand Blasting Date

6. Surface Verification OK

7. Make of Primer

8. Manufacture Date of Primer

9. Number of Primer Coating

10. Application Procedure

a. Temperature of steel surface

b. Method of application of
Epoxy

11 Place of Application

Interior / Exterior Surface

Thickness & Number of

12
Coatings

13. if any other

Signature Signature of Construction Staff Signature of Quality Control Staff

of Site In-Charge (A. E. E./DEE/EE) (A. E. E./DEE/EE)
(Contractor
Representative)

214
 O. K. CARD FOR LIQUID EPOXY COATING IN PRESSURE MAINS

S. Construction Quality
Description Contractor Remarks
No. Staff
@Nv
Staff

1. Date of Cold Tar Coating

2. Fabrication yard Number

3. Pipe Number

5. Place of Application

6. Interior / Exterior Surface

Primer Thickness
a) .
7.
b) .
c) .

Primer Coating Surface

8.
Verification OK

9. Manufacture Date of Cold Tar

10. Application Procedure

a. Temperature of steel surface

b. Method of application of
Epoxy

11. Thickness & Number of Coatings

12. if any other

Signature Signature of Construction Staff Signature of Quality Control Staff

of Site In-Charge (A. E. E./DEE/EE) (A. E. E./DEE/EE)
(Contractor
Representative)

215