ANNEXURE - I

DFCC Project, Contract CT P-12 ON SITE INSPECTION PLAN FOR RESOURCES PROCUREMENT
Inspection by and Type of
Sr. Inspection, measuring and Records to be Remarks
Material / Activity Frequency of Testing Reference Standard Specification limit for acceptance Responsibility Inspection
No. test equipment maintained
Consortium Engineer

VII Fresh Concrete

5°C< Value < 40°C

1 Temperature Records Random IS:456-2000 IS:7861-1981 Thermometer Site In charge Site Records W W
before of Placing

2 Slump Test Random IS:456-2000 IS:7320-1974 As per Mix Design Slump apparatus Site In charge Site Records W W

1-5 m³ = 1 sample,
6-15 m³ = 2 sample, 28 days Compressive Strength should be
Cube Mould 150X150X150
3 Concrete Samples (Cubes) 16-30 m³ = 3 sample, IS: 456 - 2000 as per Acceptance Criteria as per IS:456- Site In charge Cube Register W W/R
mm
31-50 m³ = 4 sample 2000.
51M³ & onward = 1sample/50m³

4 Air Content Random Max. as per 10262 2% for Concrete & 3% Shot Crete Air Entrant meter. Site In charge Site Records W W

Permeability test shall be continued for

Monthly and for the concrete of
5 Permeability of Concrete IS: 3085 - 1965 about 100 hours after the Authorised Lab Site In charge Lab test result W W
each bridge
steady state of flow has been reached

VIII Hardened Concrete RCC

1 Density of each Cube For each cube before testing IS:7325-1974 Mix Design Balance & Scale Site In charge Lab test result W -

For each (extra cast) concrete Indicative for Initial knowledge and
2 7 Days Comp. Strength IS:456-2000, IS:516-1970 CTM Site In charge Lab test result W -
sample Action, if required
28 days Compressive Strength should be
3 28 Days Comp. Strength For each concrete sample IS:456-2000, IS:516-1970 as per Acceptance Criteria as per IS:456- CTM Site In charge Lab test result W W/R
2000.

IX Batching Plant

The accuracy = < ±2 % for cement and

mineral admixtures, and within < ±3 %
1 Calibration of Plant Once in 3 month IS 4925 - 2004, IS:4926 - 2003 Weights Site In charge Lab test result W W
for Agg. , chemical admixture and water
.

2 Adjustment of Blade gap in Mixer Once / week, Plant Manual Gap for Blade 10 mm Measuring Tape and Vernier Site In charge Site Measurement W W

At the time of casting specimens

3 Density IS 1199 - 1959 As per Mix Design Balance Site In charge Lab test result W W
or one per day
For every big pours or Optional at
4 Bleeding Test / Segregation Test IS: 9103 - 1999 No Bleeding, No Segregation Bleeding Test Apparatus Site In charge Lab test result W W
the discretion of Engineer

X Bentonite

1 Liquid Limit of Bentonite Once for Source IS: 6186 - 1986, IS: 2720 Part 5 300 - 450% As per IS: 6186 Site In charge Auth Lab result W W

2 Sand Content of Bentonite Powder Once for Source IS: 6186 - 1986, IS: 2720 Part 5 7% Max. As per IS: 6186 Site In charge Auth Lab result W W

3 Differential Free Swell Once for Source IS: 6186 - 1986, IS: 2720 Part 40 540% Min. As per IS: 6186 Site In charge Auth Lab result W W

SP// Annex-1 Page 5 of 25

 ANNEXURE - I

DFCC Project, Contract CT P-12 ON SITE INSPECTION PLAN FOR RESOURCES PROCUREMENT
Inspection by and Type of
Sr. Inspection, measuring and Records to be Remarks
Material / Activity Frequency of Testing Reference Standard Specification limit for acceptance Responsibility Inspection
No. test equipment maintained
Consortium Engineer

4 pH value of Bentonite Suspension Every Pile IS: 6186 - 1986 9 - 11.5 pH Meter / pH papers Site In charge Site Test Results W R

5 Viscosity Every Pile IS: 6186 - 1986 30 - 60 Sec. Marsh Cone and Stop Watch Site In charge Site Test Results W R

Hydrometer / Digital Density

6 Density of Fresh Bentonite Suspension Every Pile IS: 6186 - 1986 1.034 - 1.10 gm/ ml Site In charge Site Test Results W R
Meter

XI Bridge Bearings

XI A POT, POT-cum-PTFE, PIN and METALLIC BEARINGS for ROAD BRIDGES

A-1 Raw materials inspection.

A Cast Steel

UTS, YS, % elongation, Ultrasonic Test

1 (Level - 3) and 1 Integral piece per Heat IS: 1030 - 1998 As per IS: 10230 At Manufacturer's Lab Site In charge MTC & Lab Results W W
Chemical Analysis

B Mild Steel

UTS, YS, % elongation, and

2 1 piece per Plate IS: 2062 - 2011 As per IS: 2062 At Manufacturer's Lab Site In charge MTC & Lab Results W W
Chemical Analysis

C Forged Steel

UTS, YS, % elongation, and

3 1 piece per Plate IS: 2004 - 1991 As per IS: 2004 At Manufacturer's Lab Site In charge MTC & Lab Results W W
Chemical Analysis

C Stainless Steel

At mill and at manufacturers

4 Chemical Tests 1 piece per Lot AISI: 316L Test Certificate Site In charge MTC & Lab Results W W
lab
D PTFE

1 Hardness From each batch at random IS: 3400 (Part – 2) - 2003 50 ± 5 IRHD At Manufacturer's Lab Site In charge MTC & Lab Results W W

2 Min. Tensile Strength From each batch at random IS: 3400 (Part – 1) - 1987 15.5 MPa At Manufacturer's Lab Site In charge MTC & Lab Results W W

3 Minimum elongation at break From each batch at random IS: 3400 (Part – 1) - 1987 Ref. Table 1 of IRC:83 (Part II)-1987 At Manufacturer's Lab Site In charge MTC & Lab Results W W

4 Maximum compression set From each batch at random IS: 3400 (Part – 10) - 1977 Ref. Table 1 of IRC:83 (Part II)-1987 At Manufacturer's Lab Site In charge MTC & Lab Results W W

5 Accelerated ageing From each batch at random IS: 3400 (Part – 4) - 1987 Ref. Table 1 of IRC:83 (Part II)-1987 At Manufacturer's Lab Site In charge MTC & Lab Results W W

E Bolts and Nuts for Bearing

IS: 1367 (Part V) - 2002,
IS: 1367 (Part V) - 2002,
1 Physical and chemical tests 1 for total lot IS: 1367 (Part VI) - 1999, MTC of Manufacturer Site In charge MTC W W
IS: 1367 (Part VI) - 1999,
IRC: 83 (Part - III) - 2002
F Washers

SP// Annex-1 Page 6 of 25

 ANNEXURE - I

DFCC Project, Contract CT P-12 ON SITE INSPECTION PLAN FOR RESOURCES PROCUREMENT
Inspection by and Type of
Sr. Inspection, measuring and Records to be Remarks
Material / Activity Frequency of Testing Reference Standard Specification limit for acceptance Responsibility Inspection
No. test equipment maintained
Consortium Engineer
1 Physical and chemical tests 1 for total lot MTC of Manufacturer Site In charge MTC W W
A-2 Inspection and testing of finished bearings.

Absence of any defects in surface finish, Inspection at Manuf.

Visual inspection
1 Every Bearing IRC: 83 (Part - III) - 2002 shape or any other Visual Inspection Site In charge Premises before W W
discernible superficial defects. despatch

Plan dimension of assembled bearing - 0 mm to + 5 mm or 0.5% of plan Standard Measuring and

2 Every Bearing IRC: 83 (Part - III) - 2002 Site In charge MTC and Test Reports W R
dimension, whichever is higher Testing equipments

- 0 mm to + 3 mm or 1% of plan Standard Measuring and

3 Overall height of assembled bearing Every Bearing IRC: 83 (Part - III) - 2002 Site In charge MTC and Test Reports W R
dimension, whichever is higher Testing equipments

Parallelism of top surface of assembled

Standard Measuring and
4 bearing w. r. t. the bottom surface as Every Bearing IRC: 83 (Part - III) - 2002 1 in 200 Site In charge MTC and Test Reports W R
Testing equipments
datum

Height of confined elastomeric pressure Standard Measuring and

5 Every Bearing IRC: 83 (Part - III) - 2002 -0 % to +5 % Site In charge MTC and Test Reports W R
pad Testing equipments

Thickness of any machined steel Standard Measuring and

6 Every Bearing IRC: 83 (Part - III) - 2002 -0 mm to +1 mm Site In charge MTC and Test Reports W R
component Testing equipments
Overall dimensions of any unmachined Standard Measuring and
7 Every Bearing IRC: 83 (Part - III) - 2002 Class 2 of IS:4897 Site In charge MTC and Test Reports W R
cast steel component Testing equipments
Standard Measuring and
8 Stainless steel sliding surface Every Bearing IRC: 83 (Part - III) - 2002 Site In charge MTC and Test Reports W R
Testing equipments
0.0004L, where L = length in direction of
8a Flatness
movement

8b Surface finish Ra ≤0.25µm as per IS:3073

A-3 Process inspection

At Manufacturer's
1 Test of welds Every Bearing IS: 822 - 1970, No crack in welds Visual and DPT Site In charge W W
Premises

For Mild Steel Not less than 120BHN,

2 Hardness Test Every Bearing IRC: 83 (Part - III) - 2002 For Cast and Forged Steel Not less than
150BHN

3 Ultrasonic Test All metal parts IS: 9565 - 1995 Level 3 of IS: 9565 - 1995

A-4 Installation of Bearings at Site

Check size vis-à-vis Bearing plate size,

1 Bedding For every bearing Visual Checking and Drawings Straightedge and filler gauges Site In charge Site Measurements W W
and surface evenness

2 Tightening of fastenings For every bearing As per Standard Practices Tight all fastenings uniformly Spanners and Torque wrench Site In charge Site Measurements W W

SP// Annex-1 Page 7 of 25

 ANNEXURE - I

DFCC Project, Contract CT P-12 ON SITE INSPECTION PLAN FOR RESOURCES PROCUREMENT
Inspection by and Type of
Sr. Inspection, measuring and Records to be Remarks
Material / Activity Frequency of Testing Reference Standard Specification limit for acceptance Responsibility Inspection
No. test equipment maintained
Consortium Engineer
Centreline within ± 3 mm of theoretical,
Level of a bearing or the mean levels of
more than one bearing at any support
within a tolerance of ± 0.0001 times the
3 Bearing Position Tolerances For every bearing IRC: 83 (Part - III) - 2002 sum of the adjacent spans of a Surveying Equipment Site In charge Site Measurements W R
continuous girder (not exceeding ± 5mm.
In a horizontal plane within a tolerance of
1 in 200 in any direction

XI B STEEL REINFORCED RUBBER BEARINGS for RAILWAY BRIDGES

B-1 Mechanical properties of rubber

MTC and Auth. Lab

1 Shore Hardness Every Lot UIC: 772 - 2R 60 ± 5 Standard Equipments Site In charge W W
Reports
MTC and Auth. Lab
2 Shear Modulus Every Lot UIC: 772 - 2R 0.8 MPa Standard Equipments Site In charge W W
Reports

6 x Mean Stress on bearing (Min)

MTC and Auth. Lab
3 Breaking strength in Compression Every Lot UIC: 772 - 2R or 8 x Mean Stress on bearing if σm is Standard Equipments Site In charge W W
Reports
between 11 - 15 MPa.

MTC and Auth. Lab

4 Bond Between Rubber and Steel 1 Piece at random from a Lot UIC: 772 - 2R No bond failure up to stress of 10MPa Standard Equipments Site In charge W W
Reports

Up to 2 Million cycles under dynamic

compressive force varying between MTC and Auth. Lab
5 Fatigue Test 1 Piece at random from a Lot UIC: 772 - 2R Standard Equipments Site In charge W W
5MPa and 10MPa with frequency of the Reports
order of 3Hz.

B-2 Mechanical properties of steel plates

MTC and Auth. Lab

1 Yield Strength 1 piece from every lot UIC: 772 - 2R 240MPa (Min) Standard Equipments Site In charge W W
Reports
MTC and Auth. Lab
2 Tensile Strength 1 piece from every lot UIC: 772 - 2R 420MPa (Min) Standard Equipments Site In charge W W
Reports
MTC and Auth. Lab
3 Thickness 1 piece from every lot UIC: 772 - 2R 1mm (Min) Standard Equipments Site In charge W W
Reports

B-3 Finished Product - Dimensions

1 Length and Width of Bearing Sheet Every Bearing UIC: 772 - 2R -0mm, +5mm Vernier Site In charge MTC and Test Results W R

2 Thickness Every Bearing UIC: 772 - 2R Vernier Site In charge MTC and Test Results W R

SP// Annex-1 Page 8 of 25

 ANNEXURE - I

DFCC Project, Contract CT P-12 ON SITE INSPECTION PLAN FOR RESOURCES PROCUREMENT
Inspection by and Type of
Sr. Inspection, measuring and Records to be Remarks
Material / Activity Frequency of Testing Reference Standard Specification limit for acceptance Responsibility Inspection
No. test equipment maintained
Consortium Engineer

2.1 Single Layer Nominal value ± 10% Vernier Site In charge MTC and Test Results W R

For Bearing Thickness

10mm to 30mm (Incl) = ±1mm
30mm to 50mm (Incl) = ±1.2mm
2.2 Overall Thickness
50mm to 80mm (Incl) = ±1.5mm
80mm to 120mm (Incl) = ±1.8mm
> 120mm = ±1.5mm

XII Sheathing Ducts

a) Length maximum as per structure

length requirements so that Splicing can
be avoided,
Physical Dimensions: a) Length Measuring tape and digital
1 Every MS Duct IRC: 112 - 2011 b) Thickness not less than 0.3 mm, 0.4 Site In charge Site Measurements W W
b) Thickness v/s dia. vernier
mm and 0.5 mm for sheathing ducts
having ID unto 50 mm, 75 mm and 90
mm resp.
a) Length maximum as per structure
length requirements so that Splicing can
be avoided,
Physical Dimensions: a) Length Measuring tape and digital
2 Every HDPE Duct IRC: 112 - 2011 b) Thickness not less than 2 mm, 2.5 Site In charge Site Measurements W W
b) Thickness v/s dia. vernier
mm, 3 mm and 4 mm for sheathing ducts
having ID unto 50 mm, 85 mm, 100 mm
and 125 mm resp.
Capable of withstanding pressure equal
MTC and Auth. Lab
3 Duct Class Every Duct IRC: 112 - 2011 to 1.1 x (maximum expected gravity head Pressure Gauges Site In charge W W
Report
of grouting material + grouting pressure)

4 Water Tightness Every Duct IRC: 112 - 2011 Must be water tight Pressure Gauges Site In charge Site Measurements W R

XIII Compression Testing Machine

IS: 1828 (Part - 1) - 2005, No leakage of Hydraulic Oil and good

1 General Conditions of CTM At installation (if old) & Yearly Visual Inspection Site In charge Lab Inspection W W
ISO: 7500-1- 1999 overall look of CTM
IS: 1828 (Part - 1) - 2005, Straight Edge and Filler
2 Inspection of the loading platens Yearly 0.01mm measured on 100mm Site In charge Lab Inspection W W
ISO: 7500-1- 1999 Gauges

IS: 1828 (Part - 1) - 2005,

3 Calibration of Dial Gauge Yearly ISO: 7500-1- 1999, IS: 4169 - Not more than ± 2% From Authorised Lab Site In charge Authorised lab result W W
19888

C BRICK MASONRY WORKS

I Anti – termite Chemicals

1 Physical Test One test for every brand proposed IS 8944 - 2005 IS 8944 - 2005 From Authorised Lab Site In charge Authorised lab result W W

2 Chemical Test One test for every brand proposed IS 8944 - 2005 IS 8944 - 2005 From Authorised Lab Site In charge Authorised lab result W W

SP// Annex-1 Page 9 of 25