TECHNICAL INSTRUCTION NO.

17

FUNCTIONS OF QUALITY CONTROL CELL IN BRO

1. INTRODUCTION

1.1 Quality Control is an important requirement in case of any Highway,

Building, Bridge, Airfield or any project with which BRO is closely associated. In
fact, it is an essential part of any production process. With the recent development
in the technological fields and various cost effective construction techniques and
expectation level of the users, quality control assumes an important role. Quality
Control, besides leading to improved quality, uniformity and ensuring a more
economical use of materials, also affords a significant reduction in user cost in
terms of vehicles’ operation, transportation and maintenance. The extra cost of
exercising quality control is usually a fraction of the resulting benefits. As brought
out in para 1.1.2 of IRC: SP-11, the expenditure on the quality control, is normally
1.5 to 2 per cent of the construction cost of any major civil engineering project. To
start wit, in BRO projects, a provision of 0.1 per cent is generally made in all Govt.
sanctions.

1.2 Though this T.I. is mainly intended for highway projects and bridges, it will
be found equally useful for a number of other projects like runway constructions.
Buildings, Airfield works, etc. This T.I. supplements the TIs already issued by
DGBR on various subjects as well as codes and standard specifications issued
from time to time by other Agencies like BIS, MOST , IRC , National Building
Code, etc.

2. AIM

2.1 To raise the level of productivity consistent with Quality as well as economy
within the framework of DGBR Technical Instructions and Specifications issued
from time to time. Standard Specifications of IRC, MOST, BIS, National Building
Code, Technical Instructions of E-in-C Branch on Airfields, etc. and other
technical bodies will be referred, in order to adopt latest technique also where
specific details are not available in DGBR Technical Instructions.

2.2 To ensure better Quality Control including getting the materials tested.

2.3 To ensure accuracy and efficiency in implementation of specifications in

work as well as in documentation.

2.4 To enhance Quality Consciousness among executives by organizing

practical tests, Courses and Seminars, etc, at different levels.
 3. REQUIREMENTS FOR QUALITY CONTROL IN WORKS

3.1 The pre-requisites for an effective and efficient Quality Control in any
construction project are:-
3.1.1 Specifications and estimates should clearly spell out the requirements for
various works.
3.1.2 Adequately trained and qualified staff and well-equipped laboratories for
exercising Quality control must exist in all projects. If necessary, suitable
candidates be got trained in National Training Centers or laboratories. Otherwise,
necessary training be imparted to qualified and selected candidates in the existing
laboratories of the Organisation.
3.1.3 Periodic appraisal for the quality control data be carried out not only for
implementation and adherence to laid down specifications during the construction
stage, but for effecting possible improvements in quality control and construction
techniques.
3.1.4 An awareness be brought in the site executives about adherence to
specifications and various codes.

31.5 Inspection and testing to be done as per Table 8.1 section 8 of IRC:SP -
112-2017 (Appx’A’)

3.1.6 List of equipment for central/ Main lab (All field Lab) shall be as per
Annexure 6.2 of IRC: SP 112-2017 (Appex’B’)

3.1.7 Inventory of Consumables’ shall be as per Annexure 6.3 of the IRC:SP -

112-2017(Appendix “C”)
3.18 Quality control for road works shall be as per section 900 of MoRTH
speciation for road and Bridge works (fifth revision ) published by IRC New
Delhi 2013 (hence for the referred as ‘Orange Book’)

4. ORGANISATION AND COMMAND & CONTROL

4.1 To ensure Quality Control in works being executed, Govt. sanction for
creation of 17 Nos Quality Control Cells (QCCs) in Headquarters Chief Engineer
Projects was accorded for 3 Year vide Govt. of India, Ministry of Surface
Transport, BRDB letter No. F.194/BRDB/P&C/CCC/85/80708/ DGBR/DS Vol I
dated 11 Apr 94, as amended vide BRDB letter of even No. dated 20 Jul94 and
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further extended for a period of one year i.e. from 01st April 1997 to 31 Mar 1998,
vide BRDB letter No. 194/BRDB/P&C/CCC/85/17846/DGBR/E2A (Estt) dated 05
Feb 1997.

4.2 Each QCC shall be manned by One Assistant Executive Engineer (Civil)
preferably a graduate and one Overseer as per Govt. sanction. Any additional
staff required, both technical and administrative, be provided by the project Chief
Engineer, from within the project resources. The officer/subordinate posted in the
QCC be well qualified/adequately trained to carry out the various tests/checks,
analyze and interpret them. In other words, they should be well qualified to carry
out various laboratory works and discharge their duties effectively.

4.3 The QCC officer shall be deployed under the direct control of the Chief
Engineer, who may appoint a suitable senior officer to supervise and guide the
activities of the QCC.

5. CHARTER OF DUTIES OF QCC OFFICER

5.1 Functions as representative of project Chief Engineer to inspect and check

the on-going works in the project to exercise Quality and advise the Chief
Engineer on matters relating to Quality Control.

5.1.1 To carry out the instructions of the Chief Engineer regarding policy matters
and work audit.

5.1.2 To arrange refresher courses and training programmers as well as help in

nomination of the staff for outside training.

5.1.3 To issue guidelines on behalf of the Chief Engineer to the executives on

ground from time to time, on quality of works in progress and suggest
improvements.

5.1.4 To keep in touch with the latest developments in the use of new materials,
quality control methods and R& D activities and formulate policies for their
adoption.

5.1.5 To interact with technical Institutes/Laboratories like IRC, BIS, CRRI, etc, as
and when required.

5.1.6 To monitor adherence to laid down specifications and standards, keep a

close watch on inspection reports of BRDB inspection Cell/Teams and to bring to
the notice of the Chief Engineer, any non-compliance and deviations thereof.

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5.1.7 Inspect works being done departmentally for ensuring no excess use/
misuse of materials, labour, vehicles, plants and equipments or any other
resources deployed.

5.1.8 To maintain proper and systematic record of the test data for major
construction work in the project for future reference.

5.1.9 To carry out any other specific inspection/work ordered by CE/HQ DGBR.

6. FUNCTIONS OF QUALITY CONTROL CELL

(METHODOLOGY)

6.1 Action at the site of work

6.1.1 Documentation: The executives will maintain the records at site as per
details given in Appendix ‘D’ and carry out testing and record the result in these
formats. The frequency of samples to be tested is given in IRC SP : 112-2017 and
Orange book and same should be followed, The QCC team will inspect these
records during their visit to site and point out shortcomings, if any , with remedial
measures suggested. An endorsement to this effect will be given by QCC team in
site record. The remedial action will be taken by executives and endorsement
made in the same records accordingly. In case of any specific requirement , not
covered in Appendix ‘D’, QCC team can suggest to executives for maintaining
additional records as per preformed given in Appendix 4 of IRC SP : 11-1988 with
marginal modifications.
6.1.2 Qualitative Analysis: The QCC team shall visit and inspect the important
stages of work in Formation Cutting, Construction of Culverts, R/Walls, B/walls,
Bridges, Airfields, Buildings, Surfacing and other Civil Engineering works being
executed in the Project .Qualitative examination involves the checking of the
various specifications adopted on ground as compared with the Adm Approvals,
adherence to technical Sanction and current DGBR Technical Instructions.
Techniques used will be studied for speed as well as economy. The utilization of
materials will be examined in relation to Quality, Economy and Efforts. Similarly,
QCC will also carry out some test checks at site and site and record their findings
in the documents.
6. 1.3 Assistance by Units/Sector commander: Units/sector commanders will
facilitate quick and efficient inspection as well as render all the necessary
assistance to the QCC team.

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 7. STANDARD CHECK LIST OF QCC

7.1 In order to speed up the inspection and standardize the procedure by the
QCC, a set of Check List has been evolved for all works as per format given in
Appendix “E”. Officer-in-charge (OIC) of QCC can also check any one or more of
the items mentioned in the list.OIC can check any other item to ensure quality.
The bridges need special attention at each stage of construction. The specific
details to be checked by QCC team during construction (stage-wise) of bridge
have been given in Appendix “F” for their guidance.

8. TECHNICAL EXAMINATION

8.1 The scope of the examination will cover the following points:-

8.1.1 Checking specifications of on-going works as per Adm Approval/Technical

Sanction and relevant Technical Instruction/Codes.

8.1.2 Examining the specifications of on-going works with a view to ascertain if

major changes/ modifications are required in future works and point out the same
for taking corrective action by concerned authority.

8.1.3 examining the post construction work and point out the deficiencies, if any,
for taking further action.

9. TEST PROCEDURES AND METGODOLOGY

9.1 Road Works& Materials: This T.I. is mainly meant to supplement and act
as a ready reckoner to various codes, standards, etc, already existing for the tests
to be carried out to ensure Quality of works under execution. IRC SP: 11 lays
down the details of tests required to be done for different items of work and
materials. The details of these tests for various works are given at Appendix ‘G’.

9.2 Airfield Works: With BRO diversifying into Airfield construction and
strengthening, a need is felt now to stipulate and standardize the minimum
requirement of tests to be carried out to ensure Quality of works. Exhaustive

instructions issued by E-in-C’s Branch from time to time on this subject, should
invariably be followed while laying down specifications for airfield works.

9.3 Concrete Pavement:- Construction of concrete pavements shall in general

follow the guidelines given in IRC: 15-2002 titled “ Standard specifications and
code of practice for construction of concrete roads”.

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9.3.1 All materials viz., cement coarse aggregates, fine aggregates, fine
aggregates and water shall be checked for conforming to the laid down
specifications
in advance of their incorporation in the work. Mix proportions for concrete shall be
pre-determined on strength basis using representative samples of materials
proposed to be actually utilized in the work. Guidance in this regard can be had
from IRC: 44-1972 and IRC: 59-1976 for “continuously” and “gap graded” mixes
respectively.

9.3.2 Quality control tests on materials as well as their frequencies shall be as

given in table 6.1 of IRC SP: 11. The general specifications for commonly used
materials are brought out in MOST (Roads Wing), “Specifications for road and
Bridge works “, published by Indian Roads congress. Fifth revision: April 2013.
These are reproduced at Appendix “H”.
9.3.3. The strength of concrete shall be ascertained either from cube or beam
specimens as specified. Sampling and testing shall be in accordance with IS:
1199 and 516 respectively.

9.3.4. The actual strength of the hardened concrete shall be ascertained by

carrying out tests on cores cut from the hardened concrete (IRC: 15-2002).

9.3.5. For any other details or requirements, IRC SP: 11 may be referred.

10. MAJOR BRIDGE WORKS

10.1 Bridges are vital infrastructure elements of a Highway net- work. Indian
Roads Congress has issued standard specifications and code of practice for
Road Bridge Sections I to VII, covering Design Criteria for prestressed concrete
road bridge and guidelines on supplemental measures for design, detailing and
durability of important bridge structures and their inspection and maintenance.
These guidelines/specifications are very exhaustive and cover all aspects of
bridge construction. A strict adherence of the various codes and specifications
stipulated therein goes a long way in achieving Quality work and durability of the
structure as a whole. Besides IRC, there are other agencies like BIS, etc., who
have published their own specifications/standards. These can be referred where
necessary.

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 11. FREQUENCY OF TESTING AND
INSPECTION BY QCC

11.1 The ideal would be to conduct tests at frequencies laid down in IRC SP: 11
as already brought out earlier. However, to avoid any undue hindrance to the
progress of works due to very frequent inspections, it would be advisable to
restrict the routine inspections by the QCC to once in two months per site. The
nature and extent of additional details to be gone into should be specified by the
Chief Engineer depending upon type of work being inspected. In addition, special

checks/ surprise checks may be ordered by Chief Engineers, as on required

basis, for important works like Bridges, Airfields, National Highways and
prestigious Building Projects.

12. TESTING EQUIPMENTS FOR LAB,

OFFICE AND LIBRARY
12.1 The minimum suggested laboratory equipments required to conduct the
various tests enumerated in the preceding paras are given in Appendix ‘F’. These
may be procured by project CEs out funds allotted to Project. Any additional
equipments to meet the requirement of a particular job may also be arranged by
the CE from funds allocated for the jobs. These facilities may be upgraded or
supplemented in a gradual manner over a period of time.
12.2 Necessary accommodation for the Lab furniture, stationery and any
additional manpower required for establishment of the QCC or its detachments
may be provided by the CEs out of their project resources.

12.3 For smooth functioning and ready reference, library facilities containing
various codes, standard and publications and any reference books, be provided to
the QCC by the respective Projects.

12.4 Where facilities for specialized tests are not available with QCC or any of
the Field Labs in BRO, the QCC may liaise with outside agencies and laboratories
to get these tests done.

13. SYSTEM OF RECORDING AND REPORTING

13.1 The QCC team will keep a record of their inspections and tests conducted
separately, Task Force wise. They shall report all their findings direct to CE
Project under intimation to TF Commanded and suggest measures where

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improvements are required. Where special inspections and tests are ordered by
HQ DGBR, they shall report direct to HQ DGBR under intimation to CE, Project.

13.2 The observations on Quality of work in progress, result of any test done at
site, or any suggestion for improvement, be endorsed in a Register kept at site
for this purpose and a copy maintained in QCC office, as per format given in
Appendix ‘J’

13.3 The details of any major short-comings or deviations from laid down norms
affecting Quality of works, wherever observed and suggested remedial measures
be forwarded to HQ DGBR (D&S Cell) half yearly so as to reach by 10 Jul and 10
Jan of every year as per format given in Appendix ‘K’

14. CONCLUSION

Border Road Organization is associated with construction of Roads,

Bridges, and Buildings & Airfields. The guidelines brought out in the T.I should be
strictly followed at all levels to ensure the desired quality and functional
requirement.

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 Appendix “A”

S Test Applicable Code Acceptance Criteria

No of Practice
A Pavement investigations
1 Visual Condition IRC: 81 IRC: 81
Survey
2 Bump integrator IRC: SP: 16:IS:3073 IRC: : SP: 16:IS:3073

3 BBD IRC: 81 IRC: 81

4 FWD IRC: 115 IRC: 115

5 Subgrade Strength IS:2720 part:16 IRC:37&CA

6 Pavement Composition ASTMC 174/174M&

MS 23 manual
B Sub –Soil investigation
1 Collection of UDS IS:1892&2132 MORTH Specification
2 Standard Penetration IS:213I for Road and & Bridge
Test Works
3 Triaxial Sheet IS:2720,Part-
11&Part-12
4 UCS IS:2720,Part-10
5 Consistency limits IS:2720,Part-5
6 Classification of Soils IS:1498
7 Silt factor IS:2720, Part-4 &
IRC-78
8 Direct Shear Test IS:2720-13
C Borrow Areas( Soil)
1 Sieve Analysis IS:2720, Part-4 MORTH Specification
2 Atterberg’s Limits IS:2720,Part-5 for Road and & Bridge
3 Compaction Test IS:2720,Part-7&8 Works
4 CBR IS:2720 Part-16
5 Free Swell Index IS:2720, Part-40

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D Quarries (Aggregate)
1 Sieve Analysis IS:2386, Part-2 MORTH Specification
2 Impact Value IS:2386,Part-4 or for Road and & Bridge
IS:5640, Part-4 Works section 1000
3 Abrasion value IS:2386,Part-4
4 Soundness IS:2386 Part-5
5 Stripping Value IS:6241 MORTH Specification
for Road and & Bridge
Works section 500

6 Water absorption IS:2386, Part-3 MORTH Specification

for Road and & Bridge
Works section
400,500,600 &1000

7 Polished stone Value BS 812,Part-114 MORTH Specification

for Road and & Bridge
Works section 500

8 Sand Equivalent Value IS:2720,Part-37 MORTH Specification

for Road and & Bridge
Works section 1000

9 Ten percent Fines IS:2386 Part-4 MORTH Specification

Value & Crushing for Road and & Bridge
Value Works section 400

E Cement
1 Consistency IS:4031,Part-4 MORTH Specification
2 Setting Time IS:4031,Part-5 for Road and & Bridge
3 Compressive Strength IS:4031,Part-6 Works section 1000
4 Fineness IS:4031 ,Part-1
5 Soundness IS:4031,Part-3

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F Bitumen
1 Penetration IS: 1203 IS:738
2 Softening Point IS: 1205

3 Ductility IS: 1208

4 Viscosity IS: 1206(Part II&III)

5 Specific Gravity IS: 1202

G Concrete Mix Design

1 Sampling IS:12062 MORTH Specification
2 Mix Design IS:12062IRC: for Road and & Bridge
SP:23& IRC: 112 Works section 1700
3 Workability IS:1199
4 Compressive Strength IS:516
5 Flexible Strength IS:516
G Asphalt Mix Design
1 Mix Design MS-2 MORTH Specification
2 Stability Testing for Road and & Bridge
3 Void Analysis Works section 500
I RE Wall
1 Fill IS:2720,Part-13, MORTH Specification
Part-4 & Part-5 for Road and & Bridge
Works section 3100

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 Appendix ’B’

LIST IF EQUIPMENTS FOR CENTRAL/MAIN LABORATORY

1. Soil Testing Equipment

a. Weigh Balances
(i) 5-20 Kg capacity –type-Accuracy 1 gm.
(ii) 500 gm capacity Electronic type-Accuracy 0.01 gm.
(iii) Electronic 5 Kg Capacity Accuracy 0.5 gm.
(iv) Chemical Balance 100 gm capacity accuracy 0.001 gm
b. Oven-electrically operated, thermostatically controlled (Including
thermometer), stainless steel dia (brass frame and steel/ or brass
wire cloth mesh) consisting if sieve sets of required sieve sizes
complete with lid.
c. Is sieves: 200 mm internal dia (brass frame and steel/ or brass wire
cloth mesh) consisting of sieve sets of required sieve sizes complete with
lid.
d. Sieve shaker capable of shaking 200 mm dai sieves- electrically
operated with time switch.
e. Stop watches 1/5 sec. Accuracy
f. Glass were compressing beakers, pipettes, dishes, measuring
cylinders (100 to 1000 cc)
g. Enamel trays
i. 600 mm x 450 mm x 5 mm
ii. 450 mm x 300 mm x 40 mm
iii. 300 mm x 250 mm x 40 mm
h. Liquid limit device with ASTM grooving tools as per IS: 2720 (Part 5).
i. Sampling pipettes fitted with pressure and suction inlets, 10 ml.
capacity.
j. Compaction apparatus (Proctor) as per IS: 2720 (Part 7) complete
with collar, base plate and hammer and all other accessories.
k. Modified AASHTO compaction apparatus as per IS: 2720 (Part 8) or
heavy compaction
l. Sand pouring cylinder with conical funnel and tap and complete as per
IS: 2720 (Part 28) including modern equipment.

m. Natural sand passes through 1 mm and retained on 600 mm as per

IS: 2720 Part 28.

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 n. Sampling tins with lids 100 mm dai x 75 mm ht. ½ kg capacity and
miscellaneous items like moisture tins with lid 50 gm etc.
o. Lab CBR testing equipment for conducting CBR testing, load frame
with 5 Tonne capacity, electrically operated with speed control as per
IS:2720 (Part 16) and consisting of following

i CBR moulds 150 mm dai-175 mm ht

ii Tripod stands for holding dial gauge
iii CBR plunger with settlement dial gauge
Iv Surcharge weight 14.7 mm dia 205 kg weight spacers
V Perforated plate (Brass)
Vi Soaking tank for accommodating CBR moulds
Vii Proving rings capacity of 10kN,20kN, 25kN and 30 kN
viii Dial gauges 25 mm travel -0.01mm/division
p Dynamic cone penetration test equipment
q Nuclear moisture density meter or equipment
r Speedy moisture meter complete with chemicals
s Rifle Box
t Deferment free swell index as per IS:270 (Part 40)
u Hydrometer and Hydrometer jar

2 Aggregate Testing Equipment

a i IS sieves of required size (450 mm, internal dia)sets as per BIS
complete with lid and pan
ii IS sieve 200 mm internal dia ( brass frame and steel/ brass wire
cloth mesh) consisting of sieve sets of required sieve sizes
complete with lid
c Enamel trays
i 600 mm x 450 mm x 50 mm
ii 450 mm x 300 mm x 40 mm
iii 300 mm x 250 mm x 40 mm
iv Circular plates of 250 mm dia

d Flakiness and Elongation index test apparatus

e Aggregate impact test apparatus as per IS: 2386 (Part-4)
f Los- Angeles abrasion test apparatus as per IS: 2386 (part 4)
g Apparatus for determination of specific of fine and coarse
aggregate as per IS:2386 (Part 3)

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 h 3 liter ,15 liter and 3 liter cylinder as per IS:2386 Part 3 for checking
bulk density of aggregate with tamping rod.
3 Cement and Cement Concrete Testing Equipment
a High frequency motor cube vibrator for testing
i Cement motor moulds (70.6 mm W x 70.6 mm L x 70.6 mm H)
b Vicar needle apparatus for setting time with plungers as per IS: 269
c Soundness testing apparatus for cement (Le Chattlier)
d Weight Balances
i 5-20 kg capacity electronic type- accuracy 1 gm
ii 500 gm capacity electronic type-accuracy 0.1 gm
iii Electronic 5 kg capacity accuracy 0.5 gm
iv 50 kg capacity electronic type-accuracy 2 gm
e Concrete mixer power driven cft capacity
f Moulds
i 150 mm x 300 mm ht, cylinder with capping component along with the
capping set.
Ii Cube 150 mm and 100 mm (each size)
g Apparatus for slump test.
h. Variable frequency and amplitude vibrating table size 1m x1 m as per
the relevant British standard
i. Compression and Flexural strength testing machine of 2000 KN
capacity with additional dial for flexural testing
j Core cutting machine with 10 cm dia, diamond cutting edge
k Leachatelier flask

4. Bitumen Testing Equipment

a Constant temperature bath for accommodating controlled(to
accommodate minimum six specimens)
b Penetrometer automatic type, including adjustable weight arrangement
and needles as per IS: 1203
c Bitumen laboratory mixer including required accessories (20 ltrs)
D Ductility meter
e Furol Viscometer
f Softening Point Test Apparatus( Ring and Ball app)
g Digital thermometer
h Rifle box
I Thin film oven test apparatus for modified binder either with PMB or
CMRB
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 J Mastic Asphalt hardness testing equipment
k Sand equipment test apertures
l Thermometers
m Gas stove and Cylinder
n Soxhlet extraction or centrifuge type apparatus complete with extraction
thimbles with solvent and filter paper
o Glass ware compressing beakers, pipettes, measuring cylinders (100 to
1000 cc and and metallic thermometers range up to 300 oc
p Hot plates 200 mm dia (1500 watt)
q Oven electrically operated, thermostatically controlled(including
thermometer), stainless steel interior from 00C to 2200C
R Canon Manning Viscometer for determination of Absolute viscosity and
Canon Fenske Viscometer d for determination of Kinematic viscosity
s Marshall stability test apparatus as per ASTM-D6327 with 25 KN and
50 KN proving ring and automatic compactor and mould for Marshall
and modified Marshall test.
t Core cutting machine suitable for up to 150 mm dia core.

5 Sub-Soil Testing Equipment

a Direct shear test apparatus having 12 variable speed and 2 KN
proving ring with all the accessories given in IS: 2720 Part 13.
b Weigh Balance
i Electronic 5 kg capacity accuracy 05 gm
ii 500 gm capacity electronic type accuracy 0.01 gm.
c Oven –electrically operated, thermostatically controlled (Including
thermometer)., stainless steel interior from 0oc to 220 oc
d Selves as per IS: 460 IS sieve 200 mm internal dia (Brass frame and
steel/ or brass wire cloth mesh) consisting of sieve sets of required sieve
sizes complete with lid and pan
e Liquid limit device with ASTM grooving tools as Per IS: 2720 (Part 5)
f Sampling pipettes fitted with pressure and suction inlets,10 mm.
Capacity
g Sampling tins with lids (100 dia x 75 mm ht) of 500 gm capacity
miscellaneous items like moisture tins with lid 50 gm etc

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 LIST OF EQUIPMENT FOR PLANT LABORATORY

Wet Mix plant

1 a Sieves as per IS:460

i IS sieves of required size 450 mm internal dia) sets as per BIS
complete with lid and pan
Ii IS sieve 200 mm internal dia,( brass frame and steel/or brass wire
cloth mesh) consisting of sieve sets of required sizes complete with
lid and pan.
b Sieve shaker capable of shaking 200 mm and 450 mm dia sieves-
electrically operated with time switch.
c Apparatus for testing Aggregate impact Value (AIV), soundness, flakness
& Elongation index, stone polishing Value.

2 Hot Mix Plant

a Sieves: as per IS1460
i IS sieve 450 mm internal dia, of sieve sets as per BIS of required sieve
sizes complete with lid and pan.
ii IS sieve 200 mm internal dia,( brass frame and steel/or brass wire
cloth mesh) consisting of sieve sets of required sizes complete with
lid.
b Sieve shaker capable of shaking 200 mm and 450 mm dia sieves-
electrically operated with time switch.
c Apparatus for testing Aggregate impact Value (AIV), soundness, flakness
& Elongation index, stone polishing Value.
d Oven-electrically operated , thermostatically controlled(Including
thermometer), staginess steel interior from 0oc to 220 oc.
e Constant temperature bath for accommodating bitumen test specimen,
electrically operated, and thermostatically controlled (to accommodate
minimum six specification.)
f Penetrometer automatic type .including adjustable weight arrangement
and needles as per IS 1203.
g Furol Viscometer
h Softening point(Ring and Ball app)
i Distant reading thermometer
j Mastic-Asphalt Hardness testing equipment
k Sand Equipment test apparatus
l Thermometers
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 m Gas stove and cylinder
n Soxhlet extraction or centrifuge type apparatus complete with extraction
thimbles with solvent and filter paper
o Glassware compressing beakers, pipettrs dishes measuring cylinders(100
to 1000 cc and metallic thermometers rand up to 300 oc)
p Hot plates 200 mm dia (1500 Watt)
q Oven –electrically operated, thermostatically controlled (Including
thermometer)., stainless steel interior from 0oc to 220 oc
3 Concrete Batching plant
a Moulds
i 150 mm x300 mm ht, Cylinder with capping component along with the
capping set.
ii Cube 150 mm and 100 mm (each size)
b Apparatus for slump test
c High frequency motor cube vibrator for cement testing
i Cement motor moulds( 70.6 mm W x Lx 6 MM H)
d Vicat needle apparatus for setting time with plungers as per IS: 269-
1967
e Soundness testing apparatus for cement (Le Chattlier)
f Weight Balance
i 5-20 kg capacity electronic type- accuracy 1 gm
ii 500 gm capacity electronic type-accuracy 0.1 gm
iii Electronic 5 kg capacity accuracy 0.5 gm
iv 50 kg capacity electronic type-accuracy 2 gm
g Variable frequency and amplitude vibrating table size 1m x1 m as per
the relevant British standard
h. Compression and Flexural strength testing machine of 2000 KN capacity
with additional dial for flexural testing
i Leachatelier flask

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 Appendix “C”

SUGGESTED INVENTORY OF CONSUMABLES

1 Soil Testing
Distilled water, filter paper , Sodium hexameter phosphate and
sodium carbonate.
2 Aggregate Testing
Sodium sultanate, Magnesium Sulphate.
3 Cement Testing
Cement , Admixtures, Distilled water ,
4 Bitumen Testing
Bitumen, Benzene, Gas cylinder , filter paper
5 Concrete Testing
Nil
6 Sub-Soil Testing
Distilled water , filter paper , sodium hexameter phosphate and
sodium carbonate

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 Appendix ‘D’ to DGBR TI No.

(Refer Para 6.1.2)

RECORD OF QUALITY CONTROL CHECKS AT SITE OF WORK

The following records, as per Performs given in Annexure mentioned against

each, will be maintained at site by executives.

1. Characteristics of Aggregate/ - Annx I to Appx ‘D’ of TI-17

Binding Material/ Screening for
WBM, Surface, Bases & Sub Base
Courses
2. Compaction Characteristics Earth- - Annx II to Appx ‘D’ of TI-17
Work/Gravel/Moorum
3. Aggregate Characteristics for - Annx III to Appx ‘D’ of TI-17
Bituminous Courses.
4. Temperature Record for Bitumen - Annx IV to Appx ‘D’ of TI-17
Work.
5. Tests of Coarse Aggregates for - Annx V to Appx ‘D’ of TI-17
Concrete
6. Tests of Fine Aggregates for - Annx VI to Appx ‘D’ of TI-17
Concrete.
7. Tests for Cement Concrete. - Annx VII to Appx ‘D’ of TI-17

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 Annexure I to Appendix ‘D’ of TI No-17

CHARACTERISTICS OF AGGREGATE/BINDING MATARIAL / SCREENING

FOR WBM, SURFACE, BASES & SUB BASE COURSES

Sl. Location Layer type Grading % Passing through IS Sieve

No. Km/m Number of _________________________________________
From aggre 100 80 63 50 40 20 12.5 10 6.3
bottom gate mm mm mm mm mm mm mm mm mm
_________________________________________________________________________

1 2 3 4 5 6 7 8 9 10 11 12 13

Aggregate Flakiness Screening

Impact index
4.75 600 300 150 75 value
mm mic mic mic mic
______________________________________________________________
% % LL PI
14 15 16 17 18 19 20 21 22
Pl value of Recorded by Remarks Action Initials Remarks
Binding Matarial (name & desig- of QCC taken of site
nation of team OIC
Officer/Supvr
%
23 24 25 26 27 28

20
 (Annexure II to Appendix “D” of TI No.17)

COMPACTION CHARACTERISTICS EARTHWROK/GRAVEL/MOORUM

--------------------------------------------------------------------------------------------------------------------------SI
KM Layer Lab Lab LOCATION WITHIN KILOMETRES
No. from OMC DD -----------------------------------------------------------------------------
bottom 0 to .1 .1 to .2 .2 to .3
-----------------------------------------------------------------------------
MC DD Ref MC DD Ref MC DD Ref
%C %C %C
1 2 3 4 5 6 7 8 9 10 11 12 13 14

LOCATION WITHIN KILOMETRES

.3 to .4 .4 to .5 .5 to .6 .6 to .7
15 16 17 18 19 20 21 22 23 24 25 26

MC DD Ref MC DD Ref MC DD Ref MC DD Ref

%C %C %C %C
Recorder by Remarks
--------------------------------------------------------------------------------------- (name & designation of
.7 to .8 .8 to .9 .9 to 1 Officer/Supvr
MC DD Ref MC DD Ref MC DD Ref
%C %C %C

27 28 29 30 31 32 33 34 35 36 37

Legend - Ref: Reference of observations sheet number (Page) and observation No.
MC: Percentage moisture content at the time of compaction.
DD : Dry Density achieved in gm/cc.
%C : Percentage Compaction.

21
 Annexure III to Appendix ‘D’ of TI No. 17

AGGREGATE CHARACTERISTICS FOR BITUMINOUS COURSES

SI Location Type of Gradation % passing through IS Sieve

No. Km/m aggregate ----------------------------------------------------------------------------
20 12.5 10 6.3 4.75 2.36 1.7 600 300
mm mm mm mm mm mm mm mm mm

1 2 3 4 5 6 7 8 9 10 11 12

Graduation % passing through IS Sieve

Aggregate Flakiness Water Stripping
Impact value Index absorption value
180 150 75
mic mic mic
% % Index % %
13 14 15 16 17 18 19 20

Recorded by Remarks of Action Taken Initials of OIC Remarks

(Name & design- QCC team
Nation of OIC/Supvr)

21 22 23 24 25

22
 Annexure IV to Appendix ‘D’ of TI No.17
TEMPERATURE RECORD FOR BITUMEN WORK

Sl Date Km/m Time conti- Temperature Recorded by

No. nuous mini- ---------------- (Name and
Mum half TA TB TM TL TR Designation of
hourly OIC/ Supvr)
1 2 3 4 5 6 7 8 9 10

_______________________________________________________________________
Remarks of QCC team Action taken Initials of Remarks
OIC Site
11 12 13 14

Legend: TA = Temperature of Aggregate

TB = Temperature of Bitumen at the time of Tack Coat

TM = Temperature of Mix

TL = Temperature while laying the Mix

TR = Temperature while Rolling

23
 Annexure V to Appendix ‘D’ of TI No.17

TESTS OF COARSE AGGREGATES FOR CONCRETE

SNo Qty. Col- Gradation@ @ @ # #

Lected ______________________ Impact Delet- Water Sound-
Cu. Mm % Passing IS Sieve size (mm) or crus- rious absorption ness
_______________________ hing consti-
Value tuents
80 40 20 12.5 10 4.25 % % %
1 2 3 4 5 6 7 8 9 10 11 12
Checked by Remarks of QCC team Action taken Initials of Remarks
(Name & OIC Site
Designation
Of offr/Supvr)
13 14 15 16 17

Maximum: @ - One test for every 50 cum of collection.

Minimum: # - One test for each source of supply and subsequently when warranted

by charge in quality of aggregate.

24
 Annexure VI to Appendix ‘D’ of TI No.17

TESTS OF FINE AGGREGATES FOR CONCRETE

Sl Qty GRADATION Deleterious@ Bulking@

No. Applied % passing I.S. Sieve size (mm)@

10 4.75 2.36 1.18 600 300 150

mm mm mm mm mic mic mic

1 2 3 4 5 6 7 8 9 10 11

Site Remarks of QCC team Action taken Initials of Remarks

Contents OIC Site

12 13 14 15 16

@ One test for every 50 cum of collection

25
 Annexure VII to Appendix ‘D’ of TI No.17

TESTS FOR CEMENT CONCRETE

SI Date Location Qty Workability Compressive Strength

No. of the (cum) ______________________________________________

Structure Slump/Compaction/ After 7 days After 28 days

factor ________________________

Veebee Value Sample Nos.

I II III IV V I II III IV V

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Checked by Remarks of QCC team Action taken Initials of Remarks

Name & OIC Site

Designation

(of offr/Supvr)

17 18 19 20 21

26
 Appendix ‘E’ to DGBR T.I. No.17

(Refer Para 7.1)

STANDARD CHECK LIST OF ITEMS OF WORKS TO BE CHECKED BY QUALITY

CONTROAL CELL TEAM

1. Test results of Soils, Materials and other Quality Control Tests carried out by QCC at
site/Laboratory may be compared with those done by Site Execution. In case of any
inconsistency, rechecking of test be carried out to establish correct values.

2. Work Documentations checked and following discrepancies noticed.

S/No Deviation Action

(a) ---------------
(b) ---------------
(c) ---------------
(d) ---------------
3. Deviations noticed and action suggested.
4. Comments on the following aspects.
(a) Imbalances of Resources at Work Site,
Affecting quality.
(b) Tools and Implements.
(c) Availability of approved working drawings.
(d) Copy of Specifications and Technical
Instructions at site.
5. Any other significant information.

27
 Appendix F to DGBR TI No. 17

(Refer Para 7.1)

QUALITY CONTROL ASPECT ON MAJOR BRIDGES

1. The following will be checked by the QCC at the time of inspection visit at
Bridge sites:-

1.1 Foundation.

1.1.1 Comparison of Plasticity index, Moisture content, Gradation, SBC and

Engineering properties of Foundation Soil actually determined with those taken in
the design. Any major variation in the SBC, Substrata or Engineering properties of
the Foundation Soil requiring review of Design should be reported.
1.1.2 Record of Approval for Foundation Levels and Strata by Accepting Officer
(Taskforce Commander in case of Departmental Construction) before laying of
Footings.
1.1.3 Where foundation Levels are decided based on No Scour criteria non-
erodability of foundation Strata to be verified.
1.1.4 Silt factor actually found during execution to be compared with that given in
the design.
1.1.5. Observance of Safety precautions.
1.2 Materials: The following should be checked in particular:-
1.2.1 Test results of materials.
1.2.2 Whether materials are taken from approved Quarries.
1.2.3. Compliance with the requirements as laid down in the clause 1000 of MOST
(Road Wing),” Specifications of road and Bridge works”, Published by IRC. Fifth
Revision: April 2013 (regarding standards of Materials and their storage).
1.2.4. Expiry date of cement.
1.3 Substructure and Superstructure

1.3.1 The stability of staging, scaffolding, shuttering, shoring, etc., to be checked.

28
1.3.2 Maintenance of quality control test results for PCC, RCC prestressing works
and backfill materials as laid down in MOST specifications for Roads & Bridge
works, IRC : 21 and IRC : 18.
1.3.3 Random checks for dimensions of various members of the structure under
construction.
1.3.4 Checks to be done for cover, spacing between bars and cables and shear
stirrups.
1.3.5 Same field tests like slump test, sieve analysis of aggregates, silt content of
sand, quality of backfill material, etc. to be carried out and test results compared
with design requirements.
1.3.6 The design of mix, quality of mix, method of vibration, curing, etc. to be
checked at site.
1.3.7 Any honey-combing, deformity or variation from the design will be reported
for remedial action.
1.3.8 Adherence to the notes and instructions given in the approved working
drawings will be checked.
1.3.9 Weep-holes filter media, compaction and quality of backfill material to be
checked.
1.3.10 Method of concreting under water and the addition of 10% extra
cement to be checked and commented.
1.3.11 Particular attention to be paid for checking of anchorages and anchor
block for prestressing work.

1.3.12 Adherence to the time and progress charts.

1.3.13 It will be verified whether the record of prestressing work is being
maintained as per Appendix 17 of MOST (Roads Wing), “Pocket Book for Bridge
Engineers,” published by IRC.

1.3.14 The levels of the bearing top surface will be checked and compared
with the approved drawings.

1.3.15 The arrangement for anchoring the expansion joint to the body of the
main deck will be checked.

1.3.16 In case of pile foundations, it may please be verified whether the

specifications given vide clause 711 of IRC: 78-2000 are being complied with.

29
1.4 Documents: It will be checked whether documents as under are
available and are being maintained for records:-
1.4.1 General investigations, Surveys and sub-soil test report.
1.4.2 Copy of Contract Agreement.
1.4.3 Approved plans and detailed working drawings.
1.4.4 Copy of AA, TS and bill of quantities.
1.4.5 Standard specifications, guidelines and codes of practices.
1.4.6 Copies of TI, relevant to the work under execution.
1.4.7 Site order book.
1.4.8 Stage passing register.
1.4.9 Time and progress charts.
1.4.10 Mix design of controlled concrete.
1.4.11 Proforma for progress of well steining and sinking
1.4.12 Proforma for recording tilts and shifts of wells.
1.4.13 Proforma for recording history of wells.
1.4.14 Statement showing particulars of wells
1.4.15 Statement showing particulars of different methods adopted and
phenomenon encountered during well sinking on different wells.
1.4.16 Recording of prestressing works.
1.4.17 Test results of aggregates used in cement concrete and road works.
1.4.18 Record of approvals accorded for foundation levels before laying of
footings.
1.4.19 Land acquisition details.
1.4.20 Details of approved quarries.
1.4.21 Test results of engineering properties of the sub-soil especially the
shear strength and compressibility, SBC of foundation soil, supporting details of
the silt factor, etc.
1.4.22 Record of issue of stores to the contractor.
1.4.23 Work Diaries, Muster Rolls, POL and Store Accounts, etc. in case of
departmental constructions.
1.4.24 Results of all quality control tests carried out during execution of work.
1.4.25 Inspection notes of visiting officers.
30
 Appendix G to TI No. 17
(Refer Para 9.1)

CONTROAL TESTS AND THEIR MINIMUM FREQUENCY FOR ROAD WORKS (Section 900)
(Reference: MOST (Roads Wing), “Specifications for Road and Bridge Works”. Published by
IRC. Fifth Revision: April 2013.
Sl. Type of Test Frequency (Min.)
No. Construction

1 Granular (i) Gradation One test per 400 m3

(ii) Atterberg limits One test per 400m3
(iii) Moisture content prior to One test per 400m2
compaction
(iv) Density of compacted layer One test per 1000m2
(v) Deleterious constituents As required
(vi) C.B.R. As required.
2 Lime/ Cement (I) Quality of lime/ cement One test for each
Stabilized soil sub- base consignment subject to
a minimum of one Test
per 5 tonne
(II) Line Cement/ Content Regularly, through
procedural Checks

(III) Degree of Pulverization Periodically as

considered necessary
(IV) CBR or Unconfined As required
Compressive Strength a set
of 3 specimens
(V) Moisture content prior to One set of test per 500
Compaction Sq .m
(VI) Density of compacted Layer One set of test per 500
Sq .m
(VII) Deleterious constituents As required
3 Water Bound Macadam (i) Aggregate Impact Value One test per 1000 M3 of
aggregate
(ii) Grading of aggregate One test per 250 M3 of
aggregate
(iii) Flakiness Index and One test per 500 M3 of
Elongation Index aggregate

31
 (iv) Altenberg limits of binding One test per 50 cubic
material meter of aggregate

(v) Atterberg limits of Portion of One test per 100 cubic

aggregate passing 425 meter of aggregate
Sieve
4 Wet Mix macadam (i) Aggregate impact value One test per 1000m3 of
aggregate

(ii) Grading of aggregate One test per 200 m3 of

aggregate

(iii) Flakiness and Elongation One test per 500 m3 of

index aggregate

(iv) Atterberg limits of Portion One test per 200 m3 of

oaggregate Passing 425 aggregate
micron Sieve

(v) Density of compacted layer One set of three test

per 1000 m2

B Test on bituminous Construction

S/No Type of construction Test Frequency (Min,)

1 Prime Coat/ Tack Coat (i) Quality of binder Number of samples per
lot and tests as per
IS:73, IS:217 and
IS:8887 as applicable
(ii) Binder temperature for At regular close intervals
application
(iii) Rate of spared of Binder Three tests per duty
2 Seal Coat / Surface (i) Quality of Binder Number of samples per
Dressing lot and tests as per
IS:73, IS:217 and
IS:8887 as applicable
(ii) Aggregate Impact Value One test per 200 m3 of
aggregate

(iii) Flakiness index and One test per 100 m3 of

Elongation Index aggregate

32
 (iv) Stripping value of aggregate One test of each source
and whenever there is
change in the quality of
aggregate
(v) Water absorption of -do-
aggregate

(vi) Water sensitivity of mix -do-

(vii) Grading of aggregate Two tests per day
(viii) Soundness(Magnesium One test of each source
Sulphate/Sodiuam Sulphate and whenever there is
change in the quality of
aggregate
(ix) Stone polishing vale -do-
(x) Temperature of binder at At regular intervals
application
(xi) Rate of spared of materials Three tests per duty
(xii) Percentage of fractured One test per 100 m3 of
faces(when gravel is used) aggregate

3 Open- graded Premix (i) Quality of binder Number of samples per

carpet mix-Seal lot and tests as per
Surfacing IS:73, IS:217 and
IS:8887 as applicable
(ii) Aggregate impact value One test per 200 m3 of
aggregate

(iii) Flakiness Index Elongation One test per 100 m3 of

Index of aggregate aggregate
(iv) Stripping value One test of each source
and whenever there is
change in the quality of
aggregate
(v) Water absorption of -do-
aggregate
(vi) Water sensitivity of mix -do-
(vii) Grading of aggregate Two tests per day
(viii) Soundness(Magnesium One test of each source
Sulphate/Sodiuam Sulphate and whenever there is
change in the quality of
aggregate
(ix) Stone polishing vale -do-

33
 (x) Temperature of binder at At regular intervals
application
(xi) Binder content Two tests per day per
plant

(xii) Percentage of fractured faces One test per 100 m3 of

aggregate

4 Bituminous Macadam (i) Quality of binder Number of samples per

lot and tests as per
IS:73, IS:217 and
IS:8887 as applicable
(ii) Aggregate impact value One test per 200 m3 of
aggregate
(iii) Flakiness Index Elongation One test per 100 m3 of
Index of aggregate aggregate
(iv) Stripping value One test of each source
and whenever there is
change in the quality of
aggregate
(v) Water absorption of -do-
aggregate
(vi) Water sensitivity of mix -do-
(vii) Grading of aggregate Two tests per day
(viii) Soundness(Magnesium One test of each source
Sulphate/Sodiuam Sulphate and whenever there is
change in the quality of
aggregate
(ix) Percentage of fractured faces One test per 100 m3 of
aggregate
(x) Binder content Periodic, subject to
minimum of two tests
per day per plant
(xi) Control of temperature of At regular intervals
binder and aggregate for
mixing and of laying and
rolling
(xii) Density of compacted layer One set of three test per
700 m2
(xiii) Rate of spared of mixed At regular intervals
material

34
5 Bituminous penetration (i) Quality of binder Two samples per lot to
Macadam/Built up be subjected to all or
spray-Grout some tests as directed
by the Engineer
(ii) Aggregate Impact Value Ne test per 200 m3 of
aggrieve
(iii) Flakiness Index and -do
Elongation Index
(iv) Striping value of aggregates’ As as mentioned
under serial No 02 (iv)
(v) Water absorption of As as mentioned
aggregates under serial No 02(v)
(vi) Aggregate grading One test per 100 m3
of aggregate
(vii) Temperature of binder at At regular close
application intervals
(viii) Rate of spared of binder One test per 500 m3 of
area
6. Dense Batumi-nous (i) Quality of binder Number of samples per
Macadam/ Semi Dense lot and tests as per
Bituminous Concrete/ IS:73 or IRC:
Bituminous Concrete SP:53,IS:15462
(ii) Aggregate Impact Value One test per 350 m3 of
aggregate.
(iii) Flakiness Index and -do-
Elongation Index of
aggregates
(iv) Soundness(Magnesium One test of each source
Sulphate/Sodium Sulphate and whenever there is
change in the quality of
aggregate
(v) Water absorption of -do-
aggregates
(vi) Sand equipment test -do-
(vii) Plasticity Index -do-
(viii) Stone Polishing Value -do-
(ix) Percentage of fractured faces One test per 350 m3 of
aggregate
(x) Mix grading One set of tests on
individual constituents
and mixed aggregate
from the dryer for each
400 tones of mix
subject to a minimum of
two tests per plant per
day

35
 (xi) Stability and voids analysis of Three tests for stability,
mix including theoretical flow value, density and
maximum specific of loose void contents for each
mix 400 tones of mix
subject to a minimum of
two tests per plant per
day
(xii) Moisture susceptibility of mix One test of each mix
(AASHTO T283) type and whenever there
is change in the quality
of source of coarse or
fine aggregate

(xiii) Control of temperature of At regular intervals

binder in boiler, aggregate in
the dryer and mix at the
time of laying and compaction
(xiv) Control of binder content & One test for each 400
gradation in the mix tones of mix subject to a
minimum of two tests
per day per plant
(xv) Rate of spared of mixed After every 5 th truck load
material
(xvi) Density of compacted layer One test per 700 m2
area
7 Recycled Material Two tests per day
Grading of aggregate
8 Cold mixes All tests as per S. No. 5
9 Quality of Modified Number of sample per
Binder lot and test as per
IS:15462
10 Geotextiles The requirement of
Section 700 shall apply

Note: For any item not covered above please refer to IRC SP: 11 and MOST (Roads Wing)
specification for Road and Bridge works” published by IRC.Fifth Revision: April 2013.

36
 Appendix H to TI No. 17
(Refer Para 9.3.2)

SPECIFICATION FOR MATERIALS

1. BRICKS: Burnet clay bricks shall conform to the requirement of IS:1077

except that the minimum compressive strength when lasted flat shall not be
less than 8.4 MPa for individual bricks and 10.5 MPa for average of 5
specimens. They shall be free from cracks and flaws and nodules of free lime.
The brick shall have smooth rectangular faces with sharp corners and emit a clear
ringing sound when struck. The size may be according to local practice with
a tolerance of # 5 per cent .

2. STONES: Stones shall be of the type specified .It shall be hard , sound
free from cracks, delay and weathering and shall be freshly quarried from an
approved quarry. Stone with round surface shall not be used.
The stones, when immersed in water for 24 hours, shall not absorb water by
more than 5 per cent of their dry weight when tested in accordance with IS: 1124.
The length of stone shall neither exceed 3 times its height nor shall they be
less than twice its height plus one joint. No stone shall be less in width than the
height and width on the base shall not be greater than three fourth of the
thickness of the wall nor less than 150 mm.
3. CEMENT: Cement to be used in the works shall be any of the following
types with the prior approval of the Engineer:-
a) Ordinary Portland Cement, 33 Grade, conforming to IS:269
b) Rapid Hardening Portland Cement, conforming to IS:8041
c) Ordinary Portland Cement, 43 Grade, conforming to IS:8112
d) Ordinary Portland Cement, 53 Grade, conforming to IS: 12269
e) Sulphate Resistant Portland Cement conforming to IS: 12300
Cement conforming to IS: 269 shall be used only after ensuring that the
minimum required design strength can be archived without exceeding the
maximum permissible cement content of 540 Kg/Cu.m of concrete.

Cement conforming to IS: 8112 and IS: 12269 may be used provided the
minimum cement content mentioned elsewhere from durability considerations is
not reduced. From strength considerations , these cements shall be used with a
37
certain as high early strength of cement in the 1 to 28 days range can be
achieved by finer grinding and higher constituent ratio of C3S/C2S where

C2S is Tricalcium Silicate and C2S is Dicalcium Silicate . In such cements, the
further growth of strength beyond say 4 weeks may be much lower than that
traditionally expected. Therefore ,further strength tests shall be carried out for
56 and 90 days to fine tune the mix design from strength considerations.
Cement conforming to IS: shall be used when sodium sulphate and
magnesium sulphate are present in large enough connection to be aggressive
to concrete. The recommended threshold values as per IS: 456 are suplhate
concentration in excess of 0.2 per cent in soil sub-strata or 300 ppm (o.03
percent) in ground water , Tests to confirm actual values sulphate concentration
are essential when the structure is located near the sea coast, chemical
fractures agricultural land sing chemical fertilizers and sites where there are
effluent discharges or where soluble sulphate bearing ground water level is
high. Cement conforming to IS: 12330 shall be carefully selected from strength
considerations to ensure that the minimum requested design strength can be
archived without exceeding the maximum permissible cement content of 540
kg/cu.m. of concrete.
Cement conforming to IS: 8041 shall be used only for precast concrete
products after specific approval of the Engineer.
Total chloride content in cement shall in no case exceed 0.05 percent by
mass of cement. Also, total sulphur content calculated as sulphuric anhydride
(SO 3) shall in no case exceed 2.5 percent and 3.0 per cent when tri-calcium
aluminate per cent by mass is up to 5 or greater than 5 respectively.

4. COARSE AGGREGATES: For plan and reinforced cement concrete (PCC

and RCC) or prestressed concrete (PSC) works, coarse aggregate shall consist of
clean , hard strong , dense non-porous and durable pieces of crushed stone-
crushed gravel, natural gravel or a suitable combination therefore or other
approved inert material. They shall not consist of place of disintegrate stones.
Soft, flaky, elongated particles salt, alkali, vegetable matter or other deleterious
materials in such quantities as to reduce the strength and durability of the
concrete, or to attack the reinforcement , Coarse aggregate having positive
alkali silica reaction shall not be used .All coarse aggregate shall conform to
IS: 383 and tests for conformity shall be carried out as per IS:2386 pars I to
VIII.

The contractor shall submit for the approval of the Engineer , the entire
information indicated in Appendix A of IS-383.

38
 Maximum nominal size coarse aggregate for various structural
components in IPC, RCC of PSC , shall conform to Section 1700 of
MOST(Roads Wing).”Specification for Road and Bridge Works”, published by
IRC. Fifth Revision: April, 2013.
The maximum value for flakiness index for coarse aggregate shall not
exceed 35 percent. The coarse aggregate shall satisfy the following
requirements of grading:
REQUIREMENTS OF COURSE AGGREGATE
Sieve Size Per cent by weight passing the Sieve
40 mm 20 mm 12.5 mm
63 mm 100 - -
40 MM 95-100 100 -
20 MM 30-70 95-100 100
12.5 MM – - 90-100
10 MM 10-35 25-55 40-85
4.75 MM 0.5 0-10 0.10

5. SAND/ FINE AGGREGATE: For masonry work, sand shall conform to the
requirement of IS: 2116.
For plan and reinforced cement concrete(PCC and RCC) or prestressed
concrete (PSC) works, fine aggregate shall consist of clean, hard strong and
durable pieces of crushed stone, crushed gravel, or a suitable combination of
natural sand , crushed stone or gravel. They shall not contain dust , lumps ,
soft or flaky materials, mica or other deleterious materials in such quantities as
to reduce the strength and durability of the concrete or to attack the embedded
steel. Motorized send washing machines should be used to remove impurities
from sand. Fine aggregate having positive alkali- silica reaction shall not be used.
All fine aggregate shall conform to IS: 383 and tests for conformity shall be
carried out as per IS:2386(Parts I to VIII). The Contractor shall submit to the
Engineer the entire information indicated in Appendix A of A IS : 383. The
fineness modulus of fine aggregate shall neither be less than 2.0 not
greater than 3.5.
Sand / Fine aggregate for structural concrete shall conform to the following
grading requirements:-

39
IS Sieve Size Per cent by Weight passing the Sieve
Zone I Zone-II Zone III
10 mm 100 100 100
4.75 mm 91-100 90-100 90-100
2.36 mm 60-95 75-100 85-100
1.18mm 3-70 55-90 75-100
600 Micron 15-34 35-59 60-79
300 Micron 5-20 8.30 12-40
150 Micron 0-10 0.10 0-10

6. STRUCTURAL STEEL:- Unless otherwise permitted herein, all structural steel shall
before fabrication comply with the requirement of the following Indian Standards:-

IS: 226 : Structural Steel (Standard Quality)

IS: 961 : Structural Steel (High Tensile)
IS: 2062 : Wieldable Structural Steel
IS: 8500 : Wieldable Structural steel (Medium & high strength qualities)
IS: 1148 : Hot rolled river bars (Up to 40 mm dia) for structural purposes.
IS: 1149 : High tensile rivet bars for structural purposes.
IS1161 : Steel tubes for structural purposes.
IS: 4923 : Hollow Steel Sections for structural use.
IS: 11587 : Structural weather resistant steel
IS: 808 : Specifications for Rolled Steel Beam, Channel and Angle Sections.
IS: 1239 : Mild Steel Tubes
IS: 1730 Dimension for Steel Plate, sheet and strip for structural and general purposes.
IS: 1731 : Dimension for Steel Flats for structural and general engineering purposes
IS1732 Dimension for round and squire steel bars for structural and general engineering
purposes
IS: 1852 : Rolling & cutting tolerances for hot steel products
. The use of structural steel not covered by the above standards may be permitted with
the specific approval of the authority.

7. WATER FOR MIXING AND CURING:- Water used for mixing and curing shall be
clean and free from injurious of oils, acids, alkalis, salts, organic materials or other
substance that may be deleterious to concrete of steel. Potable water is generally
considered satisfactory for mixing concrete Mixing and curing with sea water shall be
permitted As a guide, the following concentrations represent the maximum permissible
values:-
(a) To neutralize 200 ml sample of water phenolphthalein as an indicator, It should
not require more than 2 ml of 0.1 normal NaOH.
40
 (b) To neutralized 200 ml sample of water , using methyl orange as in indicator, It
should not require more than 10 ml of 0.1 normal HCL.
(c) The permissible limits for solids shall be as follows when tested in accordance with
IS: 3025:
Solids Permissible Limits (Max).
Organic 200 mg/ lit
Inorganic 3000mg/lit
Sulphates (SO 4) 500 mg/lit
Chlorides (CI) 500 mg/lit*
Suspended matter 2000 mg/lit
* In case of structures of length 30 m and below, the permissible limit of chlorides may be
increased up to 1000 mg/lit.
All samples of water (Including portable water) shall be tested and suitable measures
taken where necessary to ensure conformity of the water to the requirements stated herein.
(d) The pH value shall not be less than 6.
8. BITUMEN
8.1 For open graded premix carpet works of 20 mm thickness to serve as a wearing
course , the binder shall be bitumen of a suitable grade appropriate to the region, traffic,
rainfall and other environmental conditions, as directed by the Engineer and satisfying the
requirements of IS:73,217, 454 or other approved cut-backs as applicable.
8.2 For dense bituminous macadam or concrete works, the bitumen shall the paving bitumen
of penetration grade S65 or A65 (60/70) as per IS specification for paving bitumen IS: 73. IN
case of non-availability of bitumen of this grade.S90(80/100) grade may be used with the
approval of the competent engineer authority
8.3 Guidance for selection of the grade of bitumen may be taken from Annexure I of this
Appendix.
Annexure I to Appendix ” H ”. OF TI No 17

GUIDELINES ON SELECTION OF THE GRADE OF BITUMEN

(Source: Bituminous road construction handbook, Indian Oil Corporation and central road
research institute)
A For bituminous premix carpet, choice is governed by climatic conditions and intensity of
traffic.
(i) Grade 30/40 for areas where difference between maximum and minimum
atmospheric temperatures is less than 25 Degree C and traffic intensity is greater than 1500
commercial vehicles per day, for traffic intensity less than 1500 commercial vehicles per day.
Grade 50/60 is preferred.

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 (ii) Where the difference between maximum and minimum atmospheric temperature
is more than 25 Degree C and traffic intensity is greater than 1500 commercial vehicles per
day, grade 50/60 may be used. For traffic intensity of less than 1500 commercial vehicles per
day, grade 80/100 may be used. For roads with very heavy traffic greater than 4500 commercial
vehicles per day, such as metropolitan city roads, Grade 30/40 is preferred.
(iii) Grade 80/100 may be used in high altitude and snow-bound regions, irrespective
of traffic intensity consideration.

B For bituminous macadam and penetration macadam as also built-up spray grout, Grade
30/40 (for hot climates) and 60/70 or 80/100 for other climates are suggested.

C For a dense-graded bituminous concrete, a more viscous grade like 60/70 can withstand
stresses of heavier wheel loads better than a less viscous grade of 80/100. Similarly, paving
bitumen grade 60/70 is more advantageous for roads with large number of repetitions of wheel
loads like expressways, urban roads, factory roads, etc. High stability requirement cannot be
met effectively by less viscous bitumen.

D A more viscous grade of bitumen is advantageous in reducing stripping of bitumen film

from aggregates in the presence of water.

E With rounded river shingles, a more viscous grade of bitumen compensates to some
extent for poor mechanical interlock. A comparison of penetration grades and viscosity grades
(AC- 2.5 to AC- 40) of asphalt cement and AR grades (based on Rolling Thin film Over Test
residue) is shown below.

Note: - The above are commonly used materials in Road and Bridge Projects. For any item not
covered above, the specifications mentioned in the sanctioned job may be referred.

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 Appendix “ I ” to DGBR TI No.17
(Refer Para 12.1)

LIST OF TESTING EQUIPMENT REQUIRED TO BE MAINTAINED AT QUALITY CONTROL

CELL LEVEL
S/No Particulars Min requirement of QCC
1. FOR SOIL
1.1 Set of I.S. Sieves 2
1.2. Sand replacement equipment 2
1.3. Core cutter 2
1.4. Field oven 2
1.5. Electric oven 1
1.6. Proctor Mould & hammer 2
1.7. Proctor needle 2
1.8. A set of weights from 10 Kgs to 1gm 2
1.9. Pan balance (15 Kgs) 2
1.10. Load frame for testing CBR
(5 tonnes capacity) 1
1.11. CBR Moulds 10
1.12. Equipment for testing LL & PL 2
2. FOR AGGREGATES
2.1. Impact test equipment 2
2.2. Flakiness index testing equipment 2
3. FOR CONCRETE MORTAR
3.1 Slump cone & tamping rod moulds 2
Moulds
(i) 150x150x150mm 12
(ii) 70x7x70.7x70.7 12
(iii) 50x50x50mm 12
3.3 (i) Proving ring for 1 ton 1
(ii) Proving ring for 5 tons 1
4. BITUMEN
4.1 Test trays 3
4.2 Thermometers 6
4.3 Spring balance 1
5. Miscellaneous Items
Any other item like pocket steel tapes, small tools and plants, etc. If found necessary and
demanded by QCC may be provided

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 Appendix “ J ” to DGBR TI No.17
(Refer Para 13.2)

RECORDED OF INSPECTIONS BY QCC TEAM

1. Name of Task force :

2. Name of RCC/Platoon :
3. Date of Inspection :
4. Details of Inspection :
a) Name of Road :
b) Location :
c) Type of work inspected
d) Discrepancy noticed (supporting details
be kept separately) :

e) Record of samples collected be for

Tests in laboratory :

(Signature of OIC work) (Signature of OIC QCC)

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 Appendix “ K” to DGBR TI No.17

(Refer Para 13.3)

HALF YEARLY OF QUALITY CONTROL CELL

FOR HALF YEAR ENDING
Projects

S/No Type of work/Eqpt Major Short-comings Remedial Measures

Methodology in control of Quality taken

1 2 3 4

Suggestions, if any Remarks

for action by HQ DGBR

5 6

Note :Half yearly Report is to submitted to HQ DGBR/D&S Cell by 10 Jul and 10 Jan
every year by the CE Projects.

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