NATIONAL MISSION FOR CLEAN GANGA MINISTRY OF JAL SHAKTI UTTAR PRADESH JAL NIGAM - UP
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NATIONAL MISSION FOR CLEAN GANGA
MINISTRY OF JAL SHAKTI
UTTAR PRADESH JAL NIGAM
2nd TPI Report – July 2021
WAPCOS Limited
(A Government of India Undertaking – Ministry of Jal Shakti)
Corporate Office: 76-C, Institutional Area, Sector-18, 6 July 2021
Gurgaon, Haryana - 122015, India
Registered Office: “KAILASH”, 5th Floor, KG Marg, New
Delhi-110 001, India
TPI Report for Interception & Diversion and STP works at Etawah, Uttar Pradesh
Contents
SMCG TPI Report for I&D and STP works in Etawah Town
TPI REPORT BY WAPCOS FOR I&D AND STP WORKS AT ETAWAH
SECOND VISIT 16.06.2021
CONTENTS
Introduction............................................................................................................. 02
Background............................................................................................................. 02
Objectives............................................................................................................... 03
I&D works............................................................................................................... . 03
TPI Second Visit...................................................................................................... 04
Financial Provisions and Physical Progress............................................................ 04
Observations of Site Visit......................................................................................... 07
Compliance Report ................................................................... ............................ 20
1
SMCG TPI Report for I&D and STP works in Etawah Town
1 INTRODUCTION
Etawah is a city on the banks of Yamuna River in the state of Uttar Pradesh in India. It is
the administrative headquarters of Etawah District. The city was an important center for the
Revolt of 1857 (Allan Octavian Hume, the founder of Indian National Congress was district
collector then). Also is the place of sangam or confluence between Yamuna and Chambal.
It is also the site of the remains of the Great Hedge of India. The noted Hindi writer Gulabrai
was a native of Etawah.
Etawah has a rich and prosperous history. It is believed that the land existed right from the
Bronze Age in the medieval times. The earliest people of the Aryan race who once lived
here were known as the Panchalas. Even in the mythological books, Etawah appears
prominently in stories of the Mahabharata and Ramayana. During the later years, Etawah
was under the rule of the Gupta Dynasty in the fourth century AD. Etawah was an active
hub during the revolt of 1857, and multiple freedom fighters fighting against the British Raj
lived here during the tenure of the revolt. Even today, the town of Etawah houses some
remains from the Great Hedge of India, which was an inland tax line set up by the British
rulers. It has been found that the name Etawah is derived from the term used for brick
burners as there are thousands of brick centres’ near the boundaries.
2 BACKGROUND
Etawah is situated on the left bank of the River Yamuna at a distance of about 310 kms.
from Delhi. Two drains namely Tixi and Jharna were intercepted and diverted to STP at
Karanpura under YAP-I. A STP of 10.445 MLD capacity based on WSP technology was
also constructed under YAP-I. in the year 2001. These works are currently under
maintenance.
A sewerage scheme was executed in the year 2010 for the middle zone of Etawah under
state sector programme. The works under this scheme comprises of the following-
(A) Sewer line – (150 mm dia – 1200 mm dia) - 22.75 kms.
(B) Rising main (600 mm dia P.S.C. pipe) - 1.98 kms. (From Tixi to Umrain STP)
(C) M.P.S. (At Tixi) - 1 No.
(D) 13.5 MLD capacity WSP STP at Umrain - 1 No.
2
SMCG TPI Report for I&D and STP works in Etawah Town
3 OBJECTIVES
The main objectives of the detailed project report are –
I. To ascertain that no untreated sewage is discharged into river Yamuna through open
drains/nalas.
II. To identify solutions for untapped nalas carrying waste water to River Yamuna by
means of tapping arrangements, pumping station, and sewage treatment plants as
and where required.
III. To carry out the design of all sub components of the project to the level sufficient for
estimation of capital cost and O & M cost to a reasonably accurate level
IV. To ascertain additional treatment capacity required for treating waste water carried by
open drains/nalas
V. To prepare project implementation schedule.
4 I&D AND STP WORKS ETAWAH
AA&ES of the project “Interception and Diversion (I&D) and STP works of Etawah
City, Dist.Etawah” Uttar Pradesh under Namami Gange Programme at an estimated
cost of Rs. 140.60 crores under DBOT mode was granted by NMCG on 28 th
February 2019.
The main components of Interception and Diversion (I&D) and STP works of Etawah
city, District Etawah are listed as below:-
I&D of Tixi Nala.
Laying of 700mm dia DI –K7 Rising Main of 2.2 km length from MPS to STP.
Renovation of old existing MPSs at TixiNala and Karanpur.
New STP capacity of 21 MLD at Umrain.
Upgradation of existing STPs
10.445 MLD STP (C.C Lining and Chlorination System)
13.50 MLD STP ( Chlorination System)
Online monitoring system at 3 Nos. STPs automation of SPS’s Tappings and
appurtenant works.
Operation and Maintenance for 15 years for
Existing 10.455 MLD STP, 1 No. MPS with JharnaNala Tapping and appurtenant works.
Existing 13.50 MLD STP, 1 No. MPS and appurtenant works.
New 21.0 MLD STP with Tixi Nala Tapping and appurtenant works.
The period of completion of the project is 18 months after the award of the contract as
per implementation schedule given in Annexure-I.
3
SMCG TPI Report for I&D and STP works in Etawah Town
The work was awarded to M/s Vibhor Vaibhav Infra Pvt.Ltd,and M/s Baba
construction Pvt. Ltd( J.V). Raj Nagar by General Manger, Yamuna Pollution Control
Unit, U.P.Jal Nigam , Agra vide Letter No. 2100/Etawah Namami Gange/01,dated
25.06.2019 with date of start as 22.07.2019 and date of completion as 21.01.2021.
Chief Engineer, PBRBD,UP Jal Nigam has appointed M/s LN Malviya Infra projects
Pvt. Ltd. as Project Management and Construction (PMC) for projects under Namami
Gange vide CB No. -01/PMC (LNM)-S.E-IJ/2020-21 and with start of work from
14.07.2020.
Currently, the project is in construction phase.
5 TPI SECOND VISIT BY WAPCOS ON 14.06.2021
WAPCOS conducted site visit as part of TPI for I&D and STP works at Etawah on
17.06.2021. WAPCOS team comprised of following Experts:
Mr. Ravi Chandra,Top Level Expert
Mr. Suresh Kumar Chaudhary , Top Level Expert
Mr. Shubhankar Sharma, Middle Level Expert
The following officials from UP Jal Nigam and representative of Contracting firm were
present:
Mr. Chandrahaas, Project Engineer, U.P Jal Nigam,
Mr. Salim Khan, Junior Engineer, UP Jal Nigam
Mr. Manoj Sharma,Project Manager of contracting firm, namely M/s Vibhor Vaibhav
Infra Pvt Ltd., Ghaziabad were also present during TPI.
6 Project Components along with Financial provisions and physical progress are
given as under:
S. Component Financial Physical Remarks Physical
No. Provisions Progress Progress
(Rs. Crore) (Component (Overall)
wise)
1 Construction of 21 29.97 48 % Soil testing
MLD STP & survey
work has
been
completed .
4
SMCG TPI Report for I&D and STP works in Etawah Town
BEP has
been vetted
on 81.50 %
23.102.2019
SBR basin
sludge tank ,
drain sump,
CCTs for
13.50 MLD &
21 MLD
STPs ,toner
room , air
blower
building etc
are under
progress.
2 Rising Main 700 mm 2.52 64 % 1050m DI K-
dia. of 2.2 km length 7 pipe, 700
mm dia rising
main has
been laid at
site
3 Renovation 3.69 95 % Rehabilitation
/Rehabilitation of work of C.C
existing 10.445 MLD lining of
and 13.50 MLD STP ponds & CCT
/Toner room
of 10.445
MLD STP is
completed
and finishing
work is in
progress.
4 Nala Tapping 0.24 95 % I&D Works of
arrangement Tixi Nala is
under
progress.
5. Online 1.52 35.0 % -
Monitoring/LCS/MCS
for proposed STPs &
5
SMCG TPI Report for I&D and STP works in Etawah Town
existing STPs.
6. Renovation of MPS 6.70 70 % -
Financial Progress as on date is 75.58 % as intimated by U.P. Jal Nigam in monthly
progress report and attached as Annexure-II.
Overall Progress as on date is about 81.50% as intimated by U.P. Jal Nigam in
monthly progress report and attached as Annexure-II.
UP Jal Nigam has imposed liquidated damage of Rs. 93.24 lacs on the contractor for
delay in completion of the work vide letter No. 211 dated 24.12.2020 is enclosed as
Annexure-III.
Reasons for Delays -
i. Delay in the finalisation of route for laying effluent pipe of STP.
Time extension of the work extended by NMCG to October 2021 vide letter No.
350/022-0021/2021 dated 20.05.2021 and enclosed as Annexure-IV.
NMCG has approved Rs. 294.05 lacs for treated effluent pipeline works increased
scope (Discharge RCC effluent pipe 1000 mm dia. And rising main 700mm dia. DI-
K7 pipe) vide Letter No. F. No. Pr.-11013/6/2018 O/ o Dir(T-III)NMCG dated 5th
January,2021.
WAPCOS Ltd. has conducted first TPI visit on 15.12.2020. Project manager UP Jal
Nigam Etawah has submitted the compliance report to General Manager UP Jal
Nigam vide Letter No. 180/pey-26/16 Dated 27.01.2021. Remarks by WAPCOS on
compliance report is enclosed as Annexure -V
Staff employed at site:
The contractor is to employ 10 No. personnel as given in section ITB 3.3(h) (4) (ii)(b),
3.3 (h)(5) on Page 45.
10 number staff is employed at site by the contractor to be verified by UP Jal
Nigam is given as Annexure-VI.
6 No. Inspection vehicles (Two No. four wheeler (SUV) and four No. two wheeler)
are to be provided at site as per Site Office, Computer, Operator and Vehicle on
Page 192 of the Agreement.
List of vehicles verified by UP Jal Nigam to be submitted.
6
SMCG TPI Report for I&D and STP works in Etawah Town
Observations of Site Visit are as under:
S. No Item / Units Photograph Observations Recommendations
1. Project Installed.
Description
Board
7SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
2. Inlet RCC beam has RCC beam to be
Chamber varying depth repaired
and irregular
bottom.
8SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
3. SBR Basin 2 Construction
quality was
found
satisfactory.
Second foot rest Refix step
not fixed properly
9SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
4. Centrifuge
Building
Poor workmanship Needs repairs
in RCC Stair case
10SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
5. Sludge Tank Sludge sump wall
300 mm as per
drawing
11SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
6. Staff quarters Skirting height Repair required.
varying
Staff quarter
kitchen window Repair required
lintel beam
thickness varies
one end to another
end 30 mm
difference.
12SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
7. Chlorination Epoxy paint on Epoxy coating is
Contact Tank the outside to be done on
(CCT) concrete surface outer face of all
of RCC tank RCC walls.
below ground
level not
provided
13SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
8. Laboratory Proper material
testing lab has
been set up at
site.
Equipment/
Apparatus for
various tests
were found in
working
condition.
14SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
9. Tool and Mixture is being
Machinery used for minor
concreting work
and for major
concreting work
RMC is used.
Bar bending
machine was
found to be in
working
condition.
15SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
10. Cement Sagar Sulphate Daily cement
resisting consumption
Portland Cement register
cement is being to be maintained.
used at site.
Proper cement
store was set
up
Daily cement
consumption
register was not
maintained.
16SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
11. Steel Yard Reinforcement Epoxy coated
bars Fe-500 is reinforcement as
being used at per IS 13620 is
the site was not to be used as per
epoxy coated clause 12.4
as per IS Section 4 -
13620. Concrete on
page 305 of the
Agreement.
17SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
12. Safety Safety helmets Safety shoes
equipment are available at should be
and first aid site for the provided to avert
for staff and labourers and any injury for
workers staff. workers.
Medicines and
related items for
first-aid are
available
13. Labour Hutment for Proper wiring
Hutment labourers was should be
made of MS ensured to
sheet and prevent any
proper wiring untoward
has not been incident.
done which is
prone to
danger.
Toilets provided Toilets should be
for the cleaned regularly
labourers were to maintain its
found to be in hygiene and
unhygienic proper gates to
condition and be provided.
without proper
gates.
18SMCG TPI Report for I&D and STP works in Etawah Town
S. No Item / Units Photograph Observations Recommendations
Quality Assurance: Quality Assurance plan approved by the Department was available.
1. Material testing Laboratory has been set up.
2. Material quality testing register along with test results were available at site
3. The minimum frequency of sampling of concrete of each grade shall be in
accordance with Clause 15.2 of IS Code 456-2000:
Quantity of Concrete in the work, m3 No. of Samples
1-5 1
6-15 2
16-30 3
31-50 4
51 and above 4 plus one additional sample
for each additional 50 m 3
Or part thereof.
As per agreement Clause 49.3 Workmanship, page 649
For 60 cubic metre of concrete placed or for every one day’s work a
minimum of 6 (Six) cubes should be cast for test purposes.
The Frequency of testing of concrete cubes should be ensured.
Implementation of Environmental Management Plan and ESHS- MSIP as per
Appendix– I of Schedule 2 (Design Build Services) be submitted.
19Annexure- I
ANNEXURE-I
Annexure- II
ANNEXURE-II
Annexure- III
ANNEXURE-III
Annexure- IV
ANNEXURE-IV
Scanned by TapScannerScanned by TapScanner
Annexure- V
SMCG TPI Report for I&D and STP works in Etawah Town
ANNEXURE- V
Compliance report by UP Jal Nigam on TPI report dated 27.12.2020
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
1. Project Installed.
Descript
ion
Board
2. Sub- RCC beam has RCC length has been
Station varying depth provided. Nil
Building and irregular
bottom.
Lap length for 20 Lap length has been provided
mm as per drawing.
diareinforcement
in column was
600 mm instead
of 900mm.
Dimensions of
column was
found as per the
drawing.
20SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
3. Air Columns were Column has been chipped in NA
Blower found irregular plumb.
Buildin and out of plumb.
g Lintel beam of Lintel beam has been
windows were not required.
of uniform
thickness.
Width of lintel
beam and chajja Chajja has been provided 150
varying over mm on both side windows.
window opening
and not 150 mm
more than
opening of
window on each
side
RCC Beams were It has become levelled with
found projecting wall plaster.
out of walls.
Poor
workmanship was
Workmanship is being
noted.
monitored closely for
improvement.
21SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
4. SBR Construction Complied Nil
Basin 2 quality was found
satisfactory.
Cantilever slab
walkway was
found to be
irregular. As per cl 1.4 Joints
Expansion Joint Please refer IS 3370 Part 1: section 3 Civil Woks of
not provided. CI 8.3d & e. Contract agreement
d) Amongst the movement expansion joints of
joints in floors and walls as suitable gap at intervals
mentioned above, expansion not more than 30 m are
joints should normally be to be provided in walls,
provided at a spacing of not floors and roof slabs of
more than 30 m between water retaining
successive expansion joints or structures.
between the end of the Cl 8.3 d & e of IS 3370
structure and the next (Part 1) 1965 have been
expansion joints. All other modified in IS 3370 (Part
joints being of the contraction 1) 2009. Spacing of
type. joints is to be provided
e)When, however, the as per Cl 10.3.
temperature change to be Structural designer and
accommodated are abnormal Jamia Mila Islamia
or occur more frequently than Univeristy, New Delhi to
usual as in the case of clarify.
storage of warm liquids or in
un insulated roof slabs, a
smaller spacing than 30 m
should be adopted, (that is a
greater proportion of the
movement joints should be of
the expansion type) When the
range of temperature is small,
for example, in certain
elevated structures none of
the movement joints provided
in small structures upto 45 m
length need be off the
expansion type. Where sliding
joints are provided between
the walls and either the floor
or roof, the provision of
movement joints in each
22SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
element can be considered
independently.
Justification
The sentence used in code is
“should normally be provided”
indicates that the provision is
not of stringent shape and
gives some liberty for deciding
spacing of expansion joints. A
5-10% increase/decrease for
expansion joint spacing is
prerogative for structural
desining as per Code. This
point of view further
elaborated and justified in
clause e) of IS code itself,
which allows spacing up to
45m.
Further kindly be noted
following in support of
justification.
1. The proposed tank is of
regular shape i.e. not of an
irregular shape.
2. The tank is partly
underground and partly above
ground
3. The liquid/ waste water
contains do not have much
temperature variations.
Structural design has
already been vetted by
Jamia Millia Islamia
University, New Delhi.
23SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
5. Sludge Construction There is some confusion as Nil
Tank quality was well thickness is 350mm. In
satisfactory. drawing and it has been
Wall thickness provided accordingly.
was found to be
270 mm instead of
300 mm given in
the drawing
6. Staff Columns were All columns are in level/plumb Nil
quarters found irregular and with brick wall plaster.
out of plumb.
Open Joints not in Being Complied.
masonry.
Thickness of door
lintel beam was Has been provided as per
irregular. drawing.
Poor
workmanship. Workmanship is being
monitored closely for
improvement.
7. Grit Clear cover of Being Complied. Report be submitted after
Chambe reinforcement was compliance
r and irregular varying
Pre – from 15 mm to 60
mm instead of 40
Treatme
mm.
nt Unit Horizontal Being Complied.
reinforcement
bars were not
extended at the
corners as per lap
length.
24SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
8. Chlorina Epoxy paint on Being Complied. Compliance report be
tion the outside submitted.
Tank concrete surface
of RCC not
provided
9. Boundar Poor Workmanship is being Quality of workmanship
y Wall workmanship monitored closely for needs to be improved
improvement. .
Sluice valves, No- Test Report of electrical E&M equipment will be
10 Electrica return valves, mechanical equipment is checked in the next visit.
l and DI/CI pipes, attached.
Mechani transformer and
cal
equipme other electrical
nt and mechanical
25SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
equipment were
at site
10. Laborat Proper material -
ory testing lab has
been set up at
site.
Equipment/
Apparatus for
various tests were
found in working
condition.
11. Tool Mixture is being
and used for minor
Machine concreting work
ry and for major
concreting work
RMC is used.
Bar bending
machine was
found to be in
working
condition.
26SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
12. Cement Sagar Sulphate Being maintained in site. Nil
resisting Portland
cement is being
used at site.
Proper cement
store was set up
Daily cement
consumption
register was not
maintained.
27SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
13. Steel Reinforcement Being Complied. Compliance report be
Yard bars Fe-500 is The reinforcement received submitted
being used at the at site is being properly
site was not stacked. Procurement of
epoxy coated as reinforcement is being done
per IS 13620. as per quarterly requirement.
So there is no issue of
rusting. Above all, there is
reduction in the bond
strength between the coated
rebars and concrete too as
per IS 13620 clause A-5.
It is also to mention here that
use of F.B.E. coated Epoxy coated
reinforcement is not Reinforcement bars of FE
mandatory in IS: 3370 for 500 are to be provided as
“Concrete structure for per Contract Agreement.
storage of liquids” and IS:456 Competent authority to
for :Plain and Reinforced decide.
Concrete” as well.
14. Safety Safety helmets Safety shoes are available at Nil
equipme are available at site. Workers will be enforced
nt and site for the to wear safety shoes.
first aid labourers and
for staff staff. Being complied.
and Medicines and
workers related items for
first-aid are
available
28SMCG TPI Report for I&D and STP works in Etawah Town
S. Item / WAPCOS Compliance by
No Units Observations UP JAL NIGAM WAPCOS Remarks
15. Labour Hutment for Being complied. Compliance report be
Hutment labourers was submitted
made of MS Toilets are being cleaned
sheet and proper regularly. Outside opening
wiring has not MS corrugated doors are
been done which provided as it is temporary
is prone to arrangement.
danger.
Toilets provided Ages of all children of labours
for the labourers are below 4 years.
were found to be
in unhygienic
condition and
without proper
gates.
No provision
been made for
education or for
taking care for
children of
labourers at site.
29Annexure- VI
ANNEXURE-VI
Annexure- VII
ANNEXURE-VII
CONTENTS
CONTENTS
Page No.
1. FOREWARD ........................................................................................... 3
2. INTRODUCTION ..................................................................................... 3
3. TESTING ............................................................................................... 4
3.1 List of Site Testing Laboratory Equipment ........................................... 4
4. SITE INSPECTIONS ................................................................................ 5
4.1 Day to Day Supervision..................................................................... 5
4.2 Periodic Quality Inspection ................................................................ 6
4.3 Squad Checks (or as designated by Client) .......................................... 6
4.4 Quality Certification and Acceptance ................................................... 7
5. CONTROL OF MATERIALS & EQUIPMENT COMPONENTS............................... 7
5.1 General........................................................................................... 7
5.2 Materials tested on Site .................................................................... 7
6. CONTROL OF ELECTROMECHANICAL WORKS ............................................. 9
7. TEST REPORTS FOMRATS ....................................................................... 10
7.1 Test Report for Sieve Analysis (Corse Sand) ....................................... 10
7.2 Test Report for Concrete Slump ........................................................ 11
7.3 Test Report for Silt Content .............................................................. 12
7.4 Test Report for Gradation of Corse Aggregate ..................................... 13
7.5 Test Report for Bricks ...................................................................... 14
7.6 Test Report for Work Test of Concrete ............................................... 15
7.7 Test Report for Leak Test for Underground/ Elevated RCC Structure ...... 17
7.8 Concrete Pour Card ......................................................................... 18
8. INSPECTION CHECK LIST FOR CONCRETING WORK................................... 19
9. LIST OF APPLICABLE STANDARDS ........................................................... 23
VVIPL JV BCPL. Page b of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
1. FOREWARD
VVIPL JV BCPL QUALITY POLICY
Utmost care to environment and safety aspects in the deliverables
for the society.
Highest quality services of international standards to the customer.
Error free and cost effective internationally compatible services to
the customer.
Compliance with internationally established quality management
systems and it’s continual up gradation to enhance the customer
confidence level.
Qualified and experienced Quality Control professionals shall be
deployed for the entire project as per the legislative requirement.
VVIPL JV BCPL QUALITY OBJECTIVES
To provide economical services to customer.
To deliver services/deliverables on schedule.
Reduction in the cost of products thereby the cost saving to the
customers.
Keeping the client abreast with the latest technologies thereby
making the projects cost effective.
2. INTRODUCTION
Company’s (M/S VVIPL JVBCPL) Document for Quality Control (specifically
quality control at construction) provides an overview of construction quality
control activities, including testing and site inspection. Materials control
requirements are presented in detail in appendices while specific testing and
inspection requirements for each category of works are presented in appendices
of this Document.
Quality Control (QC) is intended to provide a comprehensive, common and
consistent framework for Quality Control at various construction sites. It
comprises of two main elements of quality control.
Testing
Inspection
VVIPL JV BCPL. Page 3 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
Testing Control covers the type of tests to be carried out, frequency of testing and
stage of testing. Inspection control covers the timing of inspection, item to be
inspected and the inspection procedures.
QC is affected at five stages:
Input materials and equipment components
In process activities
Stage completion
Interfacing (of special importance in water supply and sewerage projects)
Final Completion
3. TESTING
Various site tests on materials and works are required to be carried out by the
company during construction. A well equipped and properly operating site test
laboratory is established at site under the quality assurance plan. List of typical
testing apparatus to be provided at site laboratory is presented in Table 1.
Company sets-up the site laboratory at the start of the project and inform the
client. Laboratory equipment are properly calibrated, and calibration certificates
are kept at the laboratory for review by the Client, as necessary. Specialized tests
at outside laboratories (authorized laboratories) are undertaken with the prior
approval of the client.
Tests are performed in accordance with the contract documents. The control of
test reports is done as stipulated at the end of this document. All test samples are
preserved, with proper identification numbers, test log reference, test date, and
other applicable information. These samples are stored on site for the review of
the client or any statutory body.
Table 1
3.1 List of Site Testing Laboratory Equipment
The following lab testing apparatus are used at site (number of apparatus varies
as per the requirements site to site) for maintaining the quality parameters of
various site materials.
VVIPL JV BCPL
Name of Work
PROJECT NO.
S.NO. TESTING APPARATUS TYPE OF TEST REMARKS
VVIPL JV BCPL. Page 4 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
1. Balance (2 type) volume
General laboratory
measuring apparatus & hand
test
tools etc.
2. Drying and moisture
Oven
content determination
3. Grain size analysis and
Sieves, sieve shaker and
classification of soil
hydrometer
and aggregates
4. Compressive strength
Compression testing machine
of cement, concrete,
100 MT brick etc.
5. Cylinder and cube moulds Concrete sampling
6. Workability and
Slump test control of water in
concrete casting
7. Measuring instruments Measuring of sizes
8. Leak test equipment Pipeline jointing
9. Metallic contract digital Checking temperature
thermocouple of bitumen
10. Tolerances of roads
Leveling instruments
surfaces
11. Any other, specify
Note: 1) Remarks column indicate the type of apparatus put to use in the
laboratory for particular site.
In addition to tests performed on site, specialized tests are also performed at
approved laboratories, and also company takes care of factory inspections and
tests performed by manufacturers or third parties during the manufacturing of
various materials and equipment components.
4. SITE INSPECTIONS
Site inspections are carried out to ensure that the materials and construction
activities conform to the prescribed standards. Site inspections are day-to-day
supervision and periodic quality inspection as elaborated below.
4.1 Day to Day Supervision
The day-to-day site supervision of all construction activities are carried out by the
company’s engineer and client’ engineer. This includes checking of lines, levels,
layouts and on-site checks. The company in close coordination also carries out
progress monitoring and expediting is with client. The company makes sure that
materials rejected or for which a conformance report has not yet been issued are
not used in works.
Construction equipment is a major component of quality assurance system. The
equipment requirements are laid out in the contract documents. Company
provides adequate equipment required at site for construction as per the
prescribed standards and specifications. These equipments are put to inspection
by the client. The equipment used for construction is recorded in the daily logs.
VVIPL JV BCPL Page 5 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
4.2 Periodic Quality Inspection
Periodic quality inspections are carried out by the client (Engineer In Charge)
during in-process, stage completion, interfacing and final completion, and during
all critical activities as per the following examples:
Excavation
Formation of embankments
Placing of reinforcing steel
Concrete batching and pouring (100% in presence of client’s
Engineer)
Hot mix operation
Laying of pavement layers
Laying and jointing of pipes
Installation of electrical and mechanical equipment
Testing, trial runs and commissioning of electro-mechanical
equipment and plants.
The client’s (or their representative) also inspects the materials certified by
manufacturers and materials and equipment components approved by third
parties upon delivery to the site. The company gives advance notice to the client
when critical activities are proposed or major equipment items are to be
delivered.
On completion of one stage of the construction and before proceeding to the next
stage (such as from sub-base to base in road works or from steel binding to
concreting for RCC works) the engineer in charge (client’ representative) inspects
and certify the quality of the works completed before granting approval for the
next stage of the works to start. The final inspection in compasses tests on
completion and trial runs. The certification of quality is based on the documents
and the periodic site visits. The client’s representative witnesses 10%-30% (or as
per the requirements of the as set out in the contract document) of the test
conducted.
4.3 Squad Checks (or as designated by Client)
The concept of Squad Check is adopted to have an external review of quality of
works executed. The squad, client or their authorized representative) jointly
makes the quality checks. This type of check is termed as surprise check hence
no time frame is fixed.
The tentative agenda for the squad checks is described as follows:
Physical inspection of the works under execution and inspection of quality
of workmanship.
Review of site documentation and company’s compliance.
Sample verification of test reports and quality certificates
Review of issues, constraints and lacunae in quality system
implementation.
Preparing of action plans for improving the quality and
Performance appraisal of the company.
VVIPL JV BCPL Page 6 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
Minutes of progress review meetings and for interim evaluation of company’s
Performance are made
4.4 Quality Certification and Acceptance
The client (as per the contract requirements) certifies that the items included in
the contractor’s bills (RA) satisfy the required quality of works and are acceptable
with regard to the specifications and standards prescribed under the contract
before the progress bill is passed for payment.
5. CONTROL OF MATERIALS & EQUIPMENT COMPONENTS
This section provides an overview of control requirements for materials and
equipment components, including site testing, manufacturer’s certification and
third party inspection.
5.1 General
Control and approval of construction materials and equipment components to be
incorporated in the works are based on the following:
Test reports for materials tested at site, such as cement, sand, water,
aggregates and bitumen; the company performs all tests. The designated
client representative may witness as per agreement. They sign the report
in token of witnessing.
Manufacturer’s certificates and IS mark for manufactured items as per the
Contract; and
Third party inspection for various items as per contract documents.
5.2 Materials tested on Site
The materials to be tested on site include cement, water, aggregates for concrete,
bricks and stones, soil for embankments, and aggregates and bituminous
materials for road works. For aggregates and soil, the company obtains the
approval of the borrow source or quarry from the client before extracting
materials. The list of materials to be tested on site is given in Table 2 below. Test
procedures are presented in Table 3, under the referenced procedure numbers.
Test report formats are included in Appendix A. The reports are maintained in a
bound register, where in 2 copies of report are prepared, one copy to be
submitted with monthly report to the client and second copy is retained by
company.
VVIPL JV BCPL. Page 7 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
Table 2
List of Materials Tested on Site
Sl. Material
No.
1 Cement (to be procured directly from manufacturer along with his test
certificates)
2 Sand
3 Water for Construction Works (can be got tested inapproved
laboratory)
4 Size Stone
5 Coarse Aggregate for Concrete Work
6 Brick
7 Concrete
8 Steel (to be procured directly from manufacturer along with his test
certificates) this shall also be got tested in local authorized test
laboratory
Table 4.0
Procedure for Testing Materials on Site
CORSE SAND
S Type of Test Frequency of Timing of Test /
NO Test Inspection
1 Sieve Analysis One test for 25 On receipt at site and
M3 test
2 Fineness Modules One test for 25 Certificate to be
M3 produced to the
3 Silt Content One test for 25 Engineer beforeuse.
M3
4 Bulking test One test per
source
SIZE STONE
Sl. Type of Test Frequency ofTest Timing of Test /
No. Inspection
1 Dimension check As directed bythe One receipt atsite
Engineer-in-
Charge
VVIPL JV BCPL. Page 8 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
6. CONTROL OF ELECTROMECHANICAL WORKS
This section of the QA/QC Manual gives an overview of the quality control
requirements for electro-mechanical works, such as water treatment and, sewage
treatment plants, pumping systems, and power supply and distribution systems.
The requirements for testing and control of input materials and components,
including manufacturer’s certification and third party inspections.
Materials and components to be incorporated into electromechanical works are be
inspected by the client as soon as they are delivered, to ensure that they meet
the specifications and design requirements, are in agreement with shipping
documentation, and are accompanied by manufacturer’s certifications or third
party inspection certificates, as applicable. Accepted materials and equipment
shall be properly stored until needed. If manufacturer’s installation instructions
conflict with design or contract requirements, the client is notified immediately.
Installation takes place only after the conflict is resolved.
A series of inspections and tests during installation and completion of
electromechanical works are performed by the contractor or the equipment
manufacturer and witnessed by client, as follows:
Preparatory Inspections: Prior to installation, the civil and structural
works where electromechanical equipment is to be installed are inspected
to ensure conformance with designs and equipment installation
requirements.
Installation Inspection & Tests: A system of inspections and tests, as
specified in the contract or recommended by the equipment manufacturer,
are employed throughout movement to position and installation of
equipment and systems. Inspection is performed by the client at critical
points during installations. Checks are applied by client through the
progress of work to ensure that installation is performed in accordance with
the contract requirements, approved drawings, acceptable workmanship
standards and configuration control requirements. All field modifications
and retrofit work shall be performed under the supervision of the client’s
representative.
Installation verification inspections: Prior to all mechanical and
electrical testing, verification inspections are performed to ensure that
equipment has been satisfactorily installed.
System Tests: These tests are conducted as appropriate to demonstrate
that the installed systems are free from damage due to shipment and
installation, and that equipment performs in accordance with specifications.
Integrated Tests: After completion of system tests, integrated tests are
performed to demonstrate that the system performs satisfactorily when
connected to its interfacing systems or sub-systems. These tests are
followed up by commissioning tests.
Commissioning Tests: These consist of a series of tests performed under
service operating procedures to demonstrate compatibility of the physical
plant with operating procedures.
VVIPL JV BCPL. Page 9 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
Final Inspections: Final inspections are performed to ensure that the
completed work is in accordance with the contract and that all previously
identified discrepancies have been resolved satisfactorily.
7. TEST REPORTS FOMRATS
7.1 Test Report for Sieve Analysis (Coarse Sand)
UTTAR PRADESH JAL NIGAM (NAMAMI GANGE)
CONTRACTOR- VVIPL JV BCPL FORMAT NO : ............................................................ (R-0)
NAME OF THE PROJECT : Etawah Sewerage Scheme (I&D) Work
SIEVE ANALYSIS REPORT FOR Coarse Sand
Test As Per IS:383(1970) &
Source : Location :
2386(1963)
Sample No. : Sampled by : Date of Sampling :
Weight of Sample Taken : Test by : Date of Testing :
Wt. Retained Percentage Passing as per IS 383 For
% Retained on Cum % Wt.
Sieve size on each sieve % Passing Zone
each sieve Retained Zone 1 Zone 2 Zone 3
(Gms) 4
10mm 100 100 100 100
95 -
4.75mm 90 - 10 90 - 100 90 - 100
100
95
2.36mm 60 - 95 75 - 100 85 - 100 -
100
90
1.18mm 30 - 70 55 - 90 75 - 100 -
100
80
600µ 15 - 34 35 - 59 60 - 79 -
100
15
425µ 5 - 20 8 - 30 12 - 40 -
50
0 -
150µ 0-10 0 - 10 0 - 10
10
Pan
Fineness Modulus :
(Fineness modulus = Sum of Cum% of Wt Retained /100)
REMARK
CONTRACTOR PMC (LNM Infra Projects Pvt.Ltd.) UPJN
VVIPL JV BCPL. Page 10 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
7.2 Test Report for Concrete Slump
UTTAR PRADESH JAL NIGAM (NAMAMI GANGE)
CONTRACTOR VVIPL JV BCPL FORMAT NO : ...........................................(R-0)
NAME OF THE PROJECT : ETAWAH Sewerage Scheme (I&D) Work
SLUMP REPORT
Location : Pour Card No : Testing Date :
Name of Structure : Tested by : Test As per IS : 1199-1959
S. GRADE OF QUINTITY IN
DATE LOCATION TIME SLUM IN MM REMARK
NO. CONCRETE CUM
REMARKS :
CONTRACTOR PMC (LNM Infra Projects Pvt.Ltd.) UPJN
VVIPL JV BCPL. Page 11 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
7.3 Test Report for Silt Content
UTTAR PRADESH JAL NIGAM (NAMAMI GANGE)
CONTRACTOR VVIPL JV BCPL FORMAT NO :..........................................................(R0)
NAME OF THE PROJECT : Etawah Sewerage Scheme (I&D) Work
SILT CONTENT
Sampled by : Date of Sample :
Type of Material : Location :
Source : Test As per IS : 2386(1963)-2 Date of Test :
By Weight
Description 1 2
Total Weight of Dry Sample taken (W1) gm
Weight of Dry Sample after Washing through 75 mic. Sieve (W2) gm
Silt & Clay Content = ((W1-W2)/W1)*100 (%)
Average
By Volume
Capacity of Glass Measuring cylinder used :
Ml
Volume of Sand filled in Cylinder : Ml
Clean Water added to the above 100 ml Sand : Ml
The Cylinder is allowed to settle till 24hrs : Hrs
Total Volume of Sand Measured in the cylinder :(V1)
Ml
Total Volume of Sand Measured leaving silt layer :(V2) Ml
Volume of Silt thus filling the Cylinder :(V1-V2)
Ml
% of silt and clay thus observed
%
REMARKS :
< 8% for N. Sand
Limiting Values :
CONTRACTOR PMC (LNM Infra projects Pvt.Ltd.) UPJN
VVIPL JV BCPL. Page 12 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
7.4 Test Report for Gradation of Coarse Aggregate
UTTAR PRADESH JAL NIGAM (NAMAMI GANGE)
CONTRACTOR VVIPL JV BCPL FORMAT NO : .....................................(R-0)
NAME OF THE PROJECT : Etawah Sewerage Scheme (I&D) Work
GRADATION OF COARSE AGGREGATE
(I.S. 383-1970 & I.S. 2386-1963 Part I)
Sample No. : Date of Sampling :
Sampled By : Date of testing :
Location : Weight of Sample :
Source : Test By :
Individual Gradation
Max. Size of Cum. % of Requirement as
I.S Sieve Weight %of Weight % of
Aggregate Weight per I.S
(mm) Retained(gm) Retained Passing
(mm) Retained 383-1970
40 100
20 85-100
20mm 10 0-20
4.75 0-5
Pan -
12.5 100
10 85-100
10mm 4.75 0-20
2.36 0-5
Pan -
Fineness Modulus :-
Comment :-
CONTRCTOR PMC (lnm Infra Project Pvt.Ltd.) UPJN
VVIPL JV BCPL. Page 13 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
7.5 Test Report for Bricks
UTTAR PRADESH JAL NIGAM (NAMAMI GANGE)
CONTACTOR- VVIPL JV BCPL FORMAT No.- .............................(R0)
NAME OF PROJECTS:- Etawah Sewerage Scheme (I&D) Work
Consignment No. :- Testing Date:- No. Of sample collected:-
Store Entry No.:- Test as per IS:3495-1976 & IS:1077-1992 Sr.No.:-
No. Of Sample Tested :- Quantity :- ................Nos
"TEST FOR BRICKS "
(1).PHYSICAL PROPERTIES :-
Description Comments Remark
Dimensional
Conformance
Sounding
Color
Foreign Particles
Obliqueness
(2).COMPRESSIVE STRENGTH :-
Crusing
Size of Bricks Crushing Strength
Sr.No. Frog Mark Surface Area Crushing Load (T) Remark
(LxBxH) (kg/cm2)
(cm2)
(3). WATER ABSORPATION TEST :-
Wt. Of Oven
Wt. Of Wet Wt. Of Water % of Water
Sr.No. Frog Mark Dry Brick Remark
Brick (gms) Absorbed (gms) Absorbed
(gms)
Comments of Engineer/Consultant :-
Any Rectification to be done by Contractor :-
CONTRACTOR PMC (LNM Infra Projects Pvt.Ltd.) UPJN
VVIPL JV BCPL. Page 14 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
7.6 Test Report for Work Test of Concrete
Work Test of Concrete
Appendix- C
(Clause A-0 of Appendix A)
Name of work:
Name of
Contractor:
Agreement No:
Sample No:
Identification
mark:
Portion of work and quantity represented sample:
Date and time of casting cubes:
Proportion of mix: Sign. Of JE AE/AEE Contractor
7 Days test (Clause 5.4.10.3) 28 Days test (Clause 5.4.10.4)
Cubes 1. Due date of
1. Due date of test.
No. test.
2. Actual date of
1 2 3 2. Actual date of test.
test.
3. (a Minimum 3. (Min. No. of cubes to be tested-
Strength three)
(b) Maximum
Strength N/mm2 (a) Minimum Strength Cubes No.
(c) Average
Strength of three 4 5
cubes (b) Maximum Strength 6
(c) Average
(d) Difference Strength of three
between 3a & 3b cubes N/mm2
(d) Specified
compressive
(e) Difference in strength of
% age in terms of concrete mix
average strength used
i.e. 3b-3a x 100= (e) 70% of specified strength i.e. 70% of 3 (d)
3c (f) 130% of specified strength i.e. 130% of 3 (d)
4. Specified
compressive Value of 3(c ) shall be
strength of compressive strength
concrete mix used 4. If 3(b) = 3(f) and 3(a) ≥ 3(e) of sample
Sample is not acceptable,
5. a) If 3 (e) is then 28 days strenght test EE may order further
more than 30% shall be carried out. 5. If 3 (c)is more than 3 (f) investigation
b) If 3 (e) is equal
to or less than
30% than It should be restricted
proceede as to 3(f) forcomputation
below: 6. If any test value exceeds 3 (f) of strength
(i) Difference between column 4 i.e.
specifled comp. strength & column
3(c ) i.e. actual average is higher, it Strength is in order
will be denoted (+) and (-) if it is less. 7. If 3(c) ≥3 (d) but ≤ 3 (f) and concrete
VVIPL JV BCPL. Page 15 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
Concrete may be
accepted at reducad
(ii) Difference in rates in accordance
column 5(b) (i) in 3(c)-(4)x100% 8. If 3 (c) ≤3 (d) and ≥ 3 (e) with para 5.4.13.2
terms of % age of 3c Work represented by
specifled strength 9. If 3 (c) ≤ 3(e) this sample shall be
rejected and action
Accaptable & taken as prescribe in
(iii) If the Strength is clause 5.4.10.3
difference in col considered in
5(b) (i) is order
ve and the same in
terms %age of
speciflrd strength
(4) i.e. value of
5(b) (ii) is with in
(+15% range)
AE/AEE
JE Contractor AE/AEE EE JE Contractor EE
VVIPL JV BCPL. Page 16 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
7.7 Test Report for Leak Test for Underground/ Elevated RCC Structure
UTTAR PRADESH JAL NIGAM (NAMAMI GANGE)
CONTACTOR- FORMATE No.- .............................(R0)
NAME OF PROJECTS:-
NAME OF STRUCTURE :- As per IS : 3370-2 (2009)
SIZE :- LOCATION:-
"LEAK TEST FOR UNDERGROUND/ELEVATED RCC STRUCTURE"
Date of Filling Initial Water Level (m)
Observation Date Of
Water Level (m) Drop (mm) Remark
No. Observation
1
2
3
4
5
6
7
8
Comments of Engineer/Consultant :-
Any Rectification to be done by Contractor :-
PMC (LNM Infra Projects
CONTRACTOR Pvt.Ltd.) UPJN
VVIPL JV BCPL. Page 17 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
7.8 Concrete Pour Card
UTTAR PRADESH JAL NIGAM (NAMAMI GANGE)
Contractor- VVIPL JV BCPL FORMAT NO : .................................................(R-
0)
NAME OF THE PROJECT : Etawah Sewerage Scheme (I&D) Work
CONCRETE POUR CARD
Project No : Quantity : ............M3
Pour Card No : Aggregate size :
DRG No : Start Date :
Structure : Start Time :
Grade Of Concrete : Completion Date :
Slump : Completion Time :
SR. OBSERVATION BY OBSERVATION BY REMARKS IF
ITEM
NO. CONTRACTOR CONSULTANT/CLINT ANY
1 CENTER LINE CHECKED YES / NO
FORMWORK AND STAGING FOR
2 YES / NO
ACCURACY STRENGTH & FINISH
3 REINFORCEMENT CHECKED YES / NO
COVER TO REINFORCEMENT
4 YES / NO
CHECKED
BEFORE
CONCRETING VERIFYED TEST CERTIFICATE FOR
5 YES / NO
CEMENT BATCH NO/STEEL
ADEQUACY OF MATERIAL /
6 YES / NO
EQUIPMENT FOR POUR
CIVIL
EMBEDDED PARTS (LOCATION &
7 MECH.
PLUMB) CHECKED
ELEC.
S(B)
SOFFIT(S) & POUR TOP (T) LEVELS CHECKED
BEFORE (B) & AFTER (A) FORM REMOVAL (ONLY T(B)
8
OF BEAMS OF OVER 10M SPAN & IMPORTANT S(A)
STRUCTURE LIKE T.G. ETC.)
T(A)
CONSTRUCTION JOINT LOCATION & TIME (IF NOT
9
AS PER DRAWING)
10 CEMENT CONSUMPTION IN KGS
11 NUMBER OF CUBE & IDENTIFICATION MARKS
CONCRETE CONDITION OFTER FORMWORK
12 V.GOOD/GOOD/FAIR/POOR
REMOVAL
COMMENTS :
CONTRACTOR PMC (LNM Infra Projects Pvt.Ltd.) UPJN
VVIPL JV BCPL. Page 18 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
8. INSPECTION CHECK LIST FOR CONCRETING WORK
ITEMS REMARKS
Proportioning, Batching and Mixing of Concrete
The materials and proportions of concrete materials
as established by the preliminary test for mix
design should be rigidly followed.
Concrete should be produced only by weigh
batching the aggregates. The accuracy of the weigh
batcher should be periodically checked and the
needle should be adjusted to zero when the hopper
is empty. Only a mechanical mixer machine with the
hopper arrangement should be used for mixing
concrete.
The quantity of water actually entering the mixing
drum should be checked with the reading of the
gauge or valve setting, when starting a job. The
batch should be charged into the mixer so that
some water enters the drum in advance of cement
and aggregate. All water should be in the drum by
end of the first 15 seconds of the specified mixing
time. Each batch would be mixed until the concrete
is uniform in colour at least for a period of two
minutes after all the materials and water are in the
drum.
Placing of Concrete
Before any concrete is placed in the entire placing
program consisting of equipment, layout, number of
labour engaged, proposed procedures and methods
should be submitted to the Engineer-in-charge for
approval. The engineer must satisfy himself that the
arrangement for mixing and conveying concrete will
ensure that the arrangement for mixing and
conveying concrete will ensure a nearly continuous
flow of concrete during depositing, labour force
won’t be overworked affecting quality of work,
sufficient overlap is allowed between concrete
VVIPL JV BCPL. Page 19 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
placing crews working at subsequent shifts, and
sufficient lighting arrangements are made at
subsequent shifts, and sufficient lighting
arrangements are made if concreting is allowed in
the night.
The Engineer must also satisfy himself that the
concrete mix design is based on truly representative
samples of aggregate and cement which will be
actually used during concreting. While taking
representative samples from different stacks of
aggregates for checking of gradation and other
tests a scoop or shovel with sides should be used so
that the larger stones won’t roll off the side.
Before the concrete is actually placed in position,
the inside of the formwork should be inspected to
see that they have been cleaned and oiled. All
reinforcement and other items to be cast in
concrete should have clean surfaces. All
reinforcement should have sufficient cover, as
specified in the contract, which should be ensured
by using proper size cement mortar spacer blocks.
The reinforcement fabrication should be finally
checked ensuring proper length and spacing
between reinforcement bars, proper orientation
(verticality / horizontality) of reinforcement bars
and stirrups and adequate provision of development
length.
Concrete must be placed in its final position before
the cement reaches its initial set and concrete
should normally be compacted in its final position
within 30 minutes of leaving the mixer.
Concrete should be deposited as nearly as
practicable directly in its final position and should
not be re handled or caused to flow in a manner
which would cause segregation, loss of material of
displacement of reinforcement. Concrete should be
placed in the shuttering by shovels or other
approved implements and should not be dropped
for a free fall from a height more than 1.0 meter.
When it is necessary to use transfer chutes the
Engineer must satisfy himself in respect of type,
length, slopes, baffles, vertical terminals and timing
of operations. To allow for loss of mortar against
the sides of the chute, the first mixes should have
loss of mortar against the sides of the chute, the
first mixes should have less coarse aggregates.
Concrete should not be permitted to fall free from
the end of the chute by more than 1.0 M and chutes
should have slopes not flatter than 1 vertical : 3
VVIPL JV BCPL. Page 20 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
horizontal but not steeper than 1 vertical : 2
horizontal.
Concrete once started, should be continuous until
the pour is completed and would be placed in
successive horizontal layers of uniform thickness
preferably ranging from 15 to 90 cm. Concrete
should be placed as rapidly as practicable to
prevent the formation of cold joints between each
succeeding layer. The top surface of each pour and
the bedding layer should be approximately
horizontal.
Concrete should be compacted during placing with
approved vibrating equipment and consolidated to
maximum practicable density, free of pockets of
coarse aggregate, should fit tightly against all form
surfaces, reinforcements and embedded fixtures.
Caution should be exercised not to over vibrate the
concrete to the point of segregation. Tapping or
external vibration of forms by hand tool or
immersion vibrator must not be permitted and care
should be taken to prevent contact of immersion
vibrators with reinforcing steel or forms of finished
surfaces.
Concrete should be placed without interruption until
completion of part of the work between pre-
determined construction joints. If stopping of
concrete becomes unavoidable anywhere, a
properly formed construction joint shall be made
where the work is stopped. Joints should be either
vertical or horizontal. For inclined or curved
members the joint should be at right angles to the
axis of the member. The construction joint surface
should be roughened, thoroughly cleaned and
treated with a thin layer of cement group before
resumption of concreting. Except when placing with
slip forms, each placement of concrete in multiple
lift work, should be allowed to set for at least 24
hours before the start of a subsequent placement.
Curing & Protecting of Concrete
During curing of concrete preference should be
given to use of continuous spray, or ponded water,
continuously saturated covering of sacking, canvas,
hessian or other absorbent material, or approved
effective curing compounds applied with spraying
equipment capable of producing a smooth even-
textured coat.
Fresh concrete should be kept continuously wet for
a minimum period of 10 days from the date of
VVIPL JV BCPL. Page 21 of 24QUALITY ASSURANCE & QUALITY CONTROL (SPECIFIC REF. TO CONSTRUCTION)
concrete, following a lapse of 12 – 14 hours after
laying concrete. However, curing of horizontal
surface exposed to dry wind should begin
immediately after the concrete has hardened. Water
should be applied to formed surfaces immediately
upon removal of forms.
Immediately after the shuttering is removed, the
Engineer should very carefully go over the entire
surface of the concrete. Holes left by form bolts etc.
should be filled up and made good with mortar
composed of one part of cement and one and half
parts of sand passing 2.36 mm IS sieve.
Superficially honeycombed surface and rough
patches should be similarly made good immediately
after removal of shuttering and superficial water
and air holes should be filled in. The mortar should
be well worked into the surface with a wooden float
and the surface irregularities should be removed by
grinding.
If reinforcement is exposed or honey combing
occurs at vulnerable positions e.g. ends of beams or
columns it may be necessary to cut the member
partially or completely and reconstruct. The
Engineer’s decision shall be final in this regard, if
only patching is necessary, the defective concrete
should be cut till solid concrete is reached (or to a
minimum depth of 25 mm) the edges being cut
perpendicular to the affected surface or with a small
undercut if possible. Anchors, tees or dovetail slots
should also be provided wherever necessary to
attach the new concrete securely in place.
9. LIST OF APPLICABLE STANDARDS
Following is the list of applicable standards:
S.NO. INDIAN DESCRIPTION
STANDARD
1. IS : 2060 Specifications For Structural Steel.
2. IS : 8112 Specifications for ordinary Portland cement 43
grade.
3. IS : 280 Specifications for mild steel wire for general
engineering purposes.
4. IS : 383 Specifications for coarse and fine aggregate from
natural sources for concrete.
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