QUALITY CONTROL MANUAL

IRRIGATION & CAD DEPARTMENT

TELANGANA STATE

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BLANK PAGE

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 FOREWORD

The Quality Control Unit of the Irrigation & CAD Department has been restructured
with effect from 01.03.2016 with a decentralization approach viz minimum of One division
for each district and divisions have been established with effect from 01.04.2016.

The Quality Control Unit of I & CAD Dept., of Telangana state is Headed by a Chief
Engineer, Quality Control with Head quarters at Hyderabad with Two Circles One at
Hyderabad and another at Warangal and with Ten Divisions.

The Quality Control / Quality Assurance in execution is a prime requisite to ensure

longevity and performance of any Engineering work. The Quality of work can be realized
through stringent Quality Control measures jointly by Team of Members comprising of
Contractor, Construction Engineers and Quality Engineers.

The Quality Control Unit is responsible for the Quality checks of all the Major,
Medium and Minor Irrigation Projects which includes MISSION KAKATIYA. In order to
achieve the required degree of quality, it not only requires proper coordination among the
Quality Control Staff, Construction Staff and the Contractors but also the availability of a
Comprehensive Handbook on the Quality Control and Quality Assurance aspects becomes a
dire necessity which proves handy for one and all involved in the Construction Activity.

The Quality Control Manual has been available in the Quality Control Unit from a
very long time and has undergone required modifications and improvements based on the
changing requirements on the field, developments in the Engineering field, Amendments in
the Indian Standards and the experience and expertise of the Veterans of the Department.

The Manual, now prepared has been arrived at after careful study of various Quality
Control Manuals of the past of not just this Department but also after analysis of manuals of
other states and this would serve as ample guidance for its users.

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 PREFACE
It will be our endeavour that the works are executed with strict quality standards
confirming to technical specifications with deployment of good construction modalities.
Since formation of the new Telangana state it was felt that the information in the
existing manual don’t match with present scenario of fast development construction
activities. All the information are discussed and carefully examined so as to suit the present
standards.
The successful implementation of Project depends on Quality Control only. A lucid,
short and clear Quality Control Manual gives an impression of an Organisation that knows
what it is doing.
The manual of this nature cannot remain static, it has to be dynamic with continuous
upgradation of technology.
The manual shall provide understanding of the need of Quality Control, including
presenting the tests required to be conducted for the material during construction and
placement activities along with post construction scenario.
The manual is designed to introduce various formats to be followed at various stages
of construction to achieve proper quality control and transmit necessary reports. It also
provides an opportunity for Engineering personnel for deployment of their skills in Quality
Control procedures to increase useful life of structure being constructed in confirmation with
the standards.
Quality Control Manual is very comprehensive and contains not only standards of
construction materials but also guidelines for execution of works testing for QC & QA
operations. This is part of construction document also and it shall take cognizance of field
conditions.
Due care has been taken to print the Quality Control manual-2017, it is however
possible that some errors might have crept in. In case error or omission is noticed, it may be
brought to the notice of the Deputy Executive Engineer, O/o Chief Engineer, Quality Control,
Telangana.

Chief Engineer ,
Quality Control, Telangana,
Hyderabad.

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 INDEX
SL. PAGE
CHAPTER NO. DESCRIPTION
NO. NO.

1. CHAPTER – I QUALITY ASSURANCE AND CONTROL 7-25

2. CHAPTER – II ORGANISATIONAL SET-UP 26-27

3. CHAPTER – III GENERAL FUNCTIONS OF LABORATORY 28-32

4. CHAPTER – IV DUTIES OF INCHARGE OF LABORATORY 33-35

DUTIES OF FIELD STAFF IN RELATION TO

5. CHAPTER – V 36-40
QUALITY CONTROL

6. CHAPTER – VI CO-ORDINATIONS 41-43

QUALITY ASSURANCE AND INTERNAL

7. CHAPTER – VII 44-47
QUALITY AUDIT

8. CHAPTER – VIII O.K. CARDS 48-62

LIST OF REGISTERS TO BE MAINTAINED AT

9. CHAPTER – IX 63
THE SITE

DETAILS OF TESTS TO BE CONDUCTED

10. CHAPTER – X BEFORE THE WORK, DURING THE WORK & 64-80
AFTER THE WORK & LIST OF LAB EQUIPMENT

LIST OF EQUIPMENT FOR WORKS COSTING

11. CHAPTER – XI 81-82
LESS THAN 2 CRORES

LIST OF EQUIPMENT FOR WORKS COSTING

12. CHAPTER – XII 83-85
MORE THAN 2 CRORES

13. CHAPTER – XIII FORMATS OF TESTS RESULTS 86-98

IMPORTANT EXECUTION PROCEDURES AND

14. CHAPTER – XIV 99-156
SPECIFICATIONS

15. CHAPTER – XV PRESSURE MAIN 157-165

USAGE OF MANUFACTURED SAND,

16. CHAPTER – XVI GEOSYNTHETICS AND CONCRETE CANVAS 166-169
HYDRO

17. CHAPTER – XVII FREQUENCY OF TESTING 170-174

MONITORING THROUGH QUALITY CONTROL

18. CHAPTER – XVIII 175-183
CHARTS

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 i) TABLE-A - ILLUSTRATIVE DATA AND ITS
ANALYSIS FOR SETTING UP CONTROL
CHARTS OF CONCRETE STRENGTHS (Mass
Concrete)
ii) TABLE–B - ILLUSTRATIVE DATA AND ITS
ANALYSIS FOR SETTING UP CONTROL
CHARTS OF CEMENT STRENGTHS

COMPILATION OF QUALITY CONTROL DATA

19. CHAPTER – XIX 184

CHAPTER – XX DETERMINATION OF FIELD MOISTURE AND

20. 185
DRY DENSITY OF COMPACTED EARTH FILL

PLATES

1. PLATE -1A, 2A, 3A CONTROL CHARTS FOR CONCRETE 186-192

1B, 2B, 3B STRENGTHS & CEMENT STRENGTHS

ANNEXURES

SKETCH SHOWING THE ROLES AND

1. ANNEXURE – I 193-195
RESPONSIBILITY MATRIX
2. ANNEXURE – II INSPECTION AND TESTING ACTIVITIES 196
SKETCH SHOWING CONSTRUCTION
3. ANNEXURE –III 197
JOINTS IN LINING
4. ANNEXURE – IV SKETCH SHOWING AIR – WATER GUN 198
ILLUSTRATIVE SKETCH SHOWING
5. ANNEXURE – V(a) COMPACTION OF C.N.S. SOIL IN 199
DISTRIBUTORIES
ILLUSTRATIVE SKETCH SHOWING
6. ANNEXURE – V(b) TREATMENT OF CANAL PRISM IN 200
EXPANSIVE SOILS WITH CNS MATERIALS
CORRECTION FACTOR FOR HEIGHT-
7. ANNEXURE – VI 201
DIAMETER RATIO OF A CORE
DATA OF THE CORES TAKEN FROM IN
8. ANNEXURE – VII 202
SITU CONCRETE CANAL LINING
GOAP MEMO NO. 31433/REFORMS/A1/2007
DT. 28.05.2013-CANAL LINING WORKS –
9. ANNEXURE – VIII 203
COMPREHENSIVE MODALITIES AND
GENERAL GUIDELINES
GOVT. OF TELANGANA G.O. MS. NO.3
10. ANNEXURE – IX DT. 08.01.2015 - REGULARISATION OF 204-225
SAND MINING
ORGANIZATION SETUP OF CHIEF
ANNEXURE – X 226
11. ENGINEER, QUALITY CONTROL,
HYDERABAD
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 CHAPTER - I

QUALITY ASSURANCE AND CONTROL

1.0 INTRODUCTION

The importance of Quality Control of Construction Works of Irrigation Projects needs

no emphasis. Irrigation Projects involve heavy expenditure and contribute to the prosperity of
State. They are time bound programmes and require assistance from various technical bodies
for investigation, design, planning and execution. To have a safe durable structure, it is
necessary that the materials and Standard of execution fully satisfy the specifications. It is to
be recognized that while the ultimate efficiency of the performance of a project will depend
upon proper layout and designs, the ultimate health of the project during life scale of its
operational phase will depend largely on the quality achieved during its construction. Projects
have to be there for generations to come. We must take all the steps to ensure the top class
quality is maintained and there should be no compromise on this.

Each and every job whether big or how so ever small shall require to be executed to
acceptable construction quality duly conforming to sound design principles, specifications
and deployment of good methodology or modern techniques and procedures.

Quality Control/ Quality Assurance in execution is a prime requisite to ensure the

longevity and performance of any engineering system. There may be loss of human life and
the life of structure gets reduced, if the Projects are not executed properly.

Proper Implementation of these not only results in Sound Projects but also leads to
more Economy by means of Optimization. Quality Control and Quality Assurance are an
integral part of any Project.

This can be realized through stringent quality control measures jointly by the team
members comprising of: G.O.T.S., Contractor, Project Construction Team, Project Q.C.
/Q.A. Team and Design Team. The pursuit of quality shall be the cement holding these
members together in a stable pattern where each supports the other in producing a successful
project executed to acceptable quality control standards.

So as to have effective QC monitoring the Government has re-structured and

reformed the Quality Control unit by forming new divisions for ensuring minimum one QC
division for each district.

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 It is also determined to upgrade the existing laboratories with new equipment,
personnel and establish one central lab supported by a secondary lab and mobile lab in
necessary areas.

1.1 QUALITY CONTROL MANUAL

The manual of this nature cannot remain static, it has to be dynamic with continuous
upgradation of technology.

This manual is updated for the use of Irrigation Department of Telangana State. It is
based on various QA practices, IS Specifications and requirement for field/laboratory testing.
This will provide a base document outlining policy, procedure, responsible compliance
acceptance criteria and documentation for carrying out tasks related to inspection, testing and
reporting on various materials which involve for satisfactory completion of the work.

It is a very important constituent of the quality management system. It is a document

encompassing specific requirement which if fulfilled, shall help in effectively implementing
the quality control system to achieve the objective of good construction quality. It covers
broadly: the objectives, functions and operations of the construction and Q.C. Organization;
duties and responsibilities of construction and Q.C. personnel: Q.C. Organization. Q.C.
Laboratory system; O.K. Cards; Monitoring through Control Charts; Control on
workmanship; Tests on materials ; Important specifications; Quality Audit & Quality
Improvement: Standards to be adopted for material and works; Frequency of testing and
reporting; Compilation of Q.C. Data and Statistical Analysis etc; Documentation and Feed-
back ; Inspection etc.

It will prove to be a helpful guide to the Field Engineers for day to day reference and
Contractors engaged in Construction work.

1.2 ORIENTATION AND TRAINING OF CONSTRUCTION

SUPERVISION/QUALITY CONTROL STAFF

A capable and functional construction supervision (CS) and quality control / quality
assurance team is needed to ensure implementation of contract specifications. To achieve this
objective, intensive training is to be given to all related staff of construction / quality control
in suitable batches covering specifications for the works to be executed and also the
procedure to conduct various tests in the field and laboratories. I.S. codes have to be
explained in the training so as to cover key construction and QC / QA aspects.

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1.3 LABORATORY SYSTEM FOR TESTING OF INPUT AND OUTPUTS

Looking to the overall quantum of work and the scattered area in different zones,
establishment of laboratories at different levels and places forms an important link of project
organisation for quality control. The system is required to provide reliable and accurate
testing support to fulfill the objectives. Accuracy and reliability in testing will depend upon
the competence of testing personal, accuracy of apparatus, quality of reagents used, and
maintenance of requisite environmental conditions. Introduction of "Mobile testing
laboratory system" will prove to be highly result-oriented. This can be supplemented by
adequate nos. of site labs, field laboratories and zonal laboratories.

1.4 O.K. CARD SYSTEM

It is also known as Check List. It provides a systematic approach towards assuring

quality construction and has proved to be practical mechanism for enforcement of technical
specifications .For this purpose each work is divided in various activities in proper
sequence/order of construction and are listed in chronological order of occurrence in OK
card.

It provides a systematic approach towards assuring quality construction and has

proved to be practical mechanism for enforcement of technical specifications. For this
purpose, each work is divided into various activities in proper sequence/order of construction
and listed in chronological order of occurrence in O.K. Card. The cards are maintained in two
colors (Pink and Green) to be retained by construction and quality control units separately
after completion of works. During execution of work both cards are operated simultaneously
and will be kept on record by Executive Engineer concerned.

1.5 OBJECTIVES AND SCOPE OF QUALITY CONTROL

The objective of quality control management is to collect process and then communicate
the date related to the quality of inputs and outputs as well as finished item of work to those
who are responsible for the quality. Any programme of Quality Control seeks to ensure
adequacy and uniformity of quality through the following operations.

1) To ensure that works are being executed in conformity with the prescribed
specifications.
2) Inspection of storage, handling and processing facilities for all materials in conformity
with accepted or specified practice.
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 3) Monitoring the variation in specification of the materials and quantities used in the
operation of production and in the final product by suitable observation,
measurements or tests.
4) In order to achieve the common goal - Construction quality in the execution of
project, the roles and responsibility matrix, as depicted in Annexure I shall be
broadly followed by:
1. G. O. T.S
2. Project Design Team.
3. Contractor
4. Project Construction Team
5. Project QC/QA Team
5) Analysis of the observed variations by statistical or other techniques.
6) Feed-back of the results of analysis for exercise of control at each corrective steps for
maintaining the variations within specified limits.
7) Indicating expeditiously the possible remedial measures, if specifications are not likely
to be met.
8) Rejecting, where warranted, the material or the product at any intermediate or final
stage in case acceptance criteria is not satisfied.

1.6 ISSUE OF QC CERTIFICATE

In the minutes of the meeting with Chief Engineers, Quality Control held in the
chambers of Engineer-in-Chief (I) on 25.04.2009 to examine the QC procedures and
deficiencies in issue of QC certificates by the QC wing of I & CAD Department, a simple
Quality Control Certificate alongwith checkslip were finalized. It was reiterated that the
Construction and Quality Control staff should follow the guidelines scrupulously.

The Quality Control Certificate and Check slip finalized are as follows

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 QUALITY CONTROL CERTIFICATE

This is to certify that the number of Quality Control checks and tests have been conducted as per

codal provisions and observations are recorded in field registers during the execution of work in respect to

L.S. No. ( ) and part bill of the package no. ( ) and found satisfactory based on the field tests carried out.

Asst. Exec. Engr/ Asst. Engr. Dy. Exec. Engr. Exec. Engr.

CHECK SLIP FOR ISSUING QUALITY CONTROL CERTIFICATE

Name of the Construction Division/Q.C. Divn:-

Name of the Construction Sub Division/Q.C. Sub Divn:-

1. Name of Work:

2. Reference to Sanction and Amount

a) Administrative Sanction :

b) Technical Sanction:

3. Name of the Agency:

4. Reference to Agreement:

No. and Amount:

5. Reference to the Bill No. :

and Amount and M. Book

No.

6. Value of Work:

7. Value of Work covered in the present bill:

8. Details of Quality Control :

tests conducted by the

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 Construction staff and

Quality Control staff

S. Item of Work Quantit No. of Tests No. of tests Remarks

No y/ Units to be actually
. Billed conducted conducted
for
Cons Q.C. Const Q.C.
t. Staff . Staff Staff
Staff

1 2 3 4 5 6 7

a) Earthwork/

Embankment

b) Concrete

c) Materials

d) Other Items

i) Hydrostatic Test

ii) Ultrasonic Test

iii) Radiographic
Test

9. Details of Quality Control

Remarks noted in the

Placement registers and

Stage of rectifications by

Construction Staff

10.a) Details of Inspection

Reports issued by Quality

Control Inspecting Officers.

Stage of furnishing

Compliance reports by the

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 Construction Staff

b) If not furnished, probable

Date of furnishing

Compliance reports

A.E/A.E.E Dy.E.E E.E

Construction Construction Construction

A.E/A.E.E Dy.E.E E.E

Quality Control Quality Control Quality Control

1.7 QUALITY EVALUATION/OBSERVATION SHEETS (Part I & II)

The Board of Chief Engineers has made the following recommendations.

1. QC Mechanism to be adopted in the Standard Bid Document would be in two parts

i.e., static and dynamic.
2. The existing paras as proposed in the Bid document shall be static and are to be
common to all Engineering Departments.
3. The basic Q.C operations which are mandatorily to be carried-out by Construction as
well as QC Engineers of different Public Works Departments for various types of
works i.e., Dams, Canals, Reservoirs Roads, Buildings, Water supply and Sewage
works etc., at different stages of construction shall be defined and stipulated clearly in
the approved Q.C Manuals of respective Engineering Departments.
4. The approved Q.C Manual may be dynamic and shall be appended to Standard Bid
Document and shall be binding on the Contractor and the Department to be
implemented.
5. The Q.C Manual shall comprehensively cover all the Tests to be conducted,
Methodology, frequency, Establishment of Lab, Type of equipment and materials to
be used, Codal stipulations/guidelines, acceptance/rejection criteria, imposing of
penal recoveries for defective works within tolerable limits etc., for various types of
works dealt by the respective Engineering Departments.
6. The objective and scope of Q.C operations shall be specific and standardized in the
Q.C Manual.
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 7. It is opined that, mandating of QC Evaluation/Observation Report (as the case may
be) for Work bills may be at the following defined levels.

i) For all the works whose agreement value is equal to and less than Rs
50.00 lakh, requisite QC Evaluation/Observation Report shall be
mandated at final bill level.
ii) For all the works whose agreement value is more than Rs 50.00 lakh and
upto Rs. 2 Crores:
a) QC Evaluation/Observation report shall be stipulated at 1/3rd , 2/3rd and
final stages of work.
b) In respect of major Structures like Dams, Buildings and other CM&CD
works etc., the QC Evaluation/Observation report shall be insisted at
critical stages of construction i.e., Foundation level, Superstructure level
and Final level.
iii) The works of agreement value more than Rs 2.00 crore, they shall
invariably have requisite QC certificate from the concerned for all the
running and Final bills.

A Model Quality Evaluation/Observation sheet which is dynamic (has to be enriched

considering the components and nature of work and the type of tests) is enclosed as per the
nature of the work and components involved.

QUALITY EVALUATION / OBSERVATION SHEET

Office of the Executive Engineer, QC&I Division No.
Name of the QC Sub Division/
1
Division
Name of the Construction Sub
2
Division/ Division

3 Name of the Work

Reference to Administrative
4
Sanction and Amount
Reference to Technical
5
Sanction and Amount
Reference to Agreement No
6
and Amount

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 7 Name of the Agency

Reference to Bill No and Value

8
of work Covered in this bill

9 MB No :

AGREEMENT PROVISIONS

MB Quantity
Item Agreement RE
Component Remarks
No. Quantity Quantity 1st & 2nd &
Total
Part Final

1 Jungle Clearance

2 Desilting

3 Stripping

Benching(if permitted in the

4
agreement)

5 Embankment

i) COT

Casing Embankment using Semi-

ii)
pervious

iii) Embankment with Hearting soils

6 Filters

7 EWE for Structures (Foundation)

8 EWE for Irrigation Channels

9 Concrete
i) M-10
ii) M-15
iii) M-20
iv) M-25
v) M-30
vi) M-35
vii) M-40

viii) Concrete of any other grade

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 10 Dismantling

11 Revetment

12 MS Shutters

13 Laying & Jointing of NP2 Pipes

Supply & Delivery of NP2 class

14
Pipes

15 Steel

16 Grouting

17 Shotcreting

18 Bearings

19 Financial Progress (Rs)

20 Other Items if any

ABSTRACT OF DETAILS OF TESTS

No. of Refe
No. Of
tests renc
Tests to No. Of
condu e of
be tests
Work cted Regi
Frequency conducted actually
S.No. Description of the Item done by ster
of Test by QC@ conduct
Quantity Constr No
10% of ed by
uction with
the QC
staff page
frequency
No.
1 2 3 4 5 6 7 8
1 EWE & FE

a) Field Compaction Test

b) Permeability Test

c) Gradation Analysis

2 Cement Concrete

a) Sieve Analysis For CA

b) Sieve Analysis For FA

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 c) Slump Test

d) Temperature Test

e) Concrete Cube Test

f) Core Test for Hardened
Concrete
h) Non Destructive Test
(Rebound Hammer )for
Hardened Concrete
3 Revetment

a)Size of stone

b) Thickness of Revetment

4 Reinforcement

Tests for Electromechanical

5
and Hydromechanical
a) No.of tests witnessed for PSC
Pipes
b) No.of tests witnessed for
HDPE Pipes
c) No.of tests witnessed for
Pumps
d) No.of tests witnessed for
Motors
6 Hydrostatic

7 Ultrasonic

8 Radiographic

9 Tunneling

i) Alignment with coordinates

ii) Lining
iii) Shot creting
iv) Seepage levels

Note: The above tests are indicative. Add any other required tests as per the necessity or
as per the Schedule A.

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 QUALITY EVALUATION / OBSERVATION SHEET

Office of the Executive Engineer, QC&I Division No.

1 Name of the Work

Ref to Agreement No and

2
Amount

3 Name of the Agency

Observations
I. FORMATION/RAISING OF EMBANKMENT

a) The Field Compaction Test is conducted and the details are as follows

Name &
Sl Loca Test Compaction Register No
Designation Date Remarks
No tion Result Efficiency with Page No
of QC Staff

b) The top width of bund and T.B.L are verified and the details are as follows.

Name & T/W of bund T.B.L Register No

Sl
Location Designation Date Obser Requi Observ Requi with Page Remarks
No
of QC Staff ved red ed red No

c) COT is Verified and the details are as follows

Bottom width Bottom level of
Name & Register No
Sl of COT COT
Location Designation Date with Page Remarks
No Obser Requi Observ Requi
of QC Staff No
ved red ed red

d) Excavation - The bed width of the Canal and bed levels are Verified and the details are as
follows

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 Bottom width
Name & Bed Level Register
Sl of Canal
Location Designation Date No with Remarks
No Obser Requi Observ Requi
of QC Staff Page No
ved red ed red

e) Desilting - The prelevels / post levels of silt are verified and the observations are
recorded.

Name &
Sl Location Date Of Pre Date of Post Register No
Designation Remarks
No /Grid Levels Levels with Page No
of QC Staff

2. CEMENT CONCRETE
a. The C.C work measurements are verified and the details are as follows.
Dimensions
Register
Name & Rem
Descripti Height/Thick No with
Sl Designat Length Width arks
on/ Date ness Page No
No ion of
Location
QC Staff
Obser Requi Obser Requi Obser Requi
ved red ved red ved red

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 b. Sieve Analysis Tests Conducted Details

Regist
Name & No. of tests No. of tests er No
SlN Location/
Description Date Designation to be actually with Remarks
o chainage
of QC Staff Conducted Conducted Page
No
Sieve
Analysis
for Fine
Aggregate
Sieve
Analysis
for Coarse
Aggregate
(10 mm)
Sieve
Analysis
for Coarse
Aggregate
(20 mm)
Sieve
Analysis
for Coarse
Aggregate
(40 mm)

c. Concrete -Core Tests Conducted Details

No. of Register
No. of Tests
Sl Grade of Quantity Cube Tests No with
actually Remarks
No Concrete Executed to be Page
Name & conducted
conducted No
Designation of
QC Staff
1

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d. Concrete Cube- Core Tests Conducted Details

No. of Register
No. of
Grade of Quantity Name & Tests No with
SlNo Tests to be Remarks
Concrete Executed Designation actually Page
conducted
of QC Staff conducted No
1

3.REVETMENT

The revetment thickness is verified and the details are as follows.

Thickness of
Name & Slope length Register
Sl Location/ revetment
Designation Date No with Remarks
No chainage Obser Requi Obser Requi
of QC Staff Page No
ved red ved red

4.Reinforcement
The reinforcement of Structures are verified and the details are as follows.

Description & Name & Dia of bar Spacing Register

Sl
Diameter of Designation Date Obser Requi Obser Requi No with Remarks
No
bars of QC Staff ved red ved red Page No

5.Pipelines/Pressure-Mains
The tests are witnessed and the details are as follows.

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i) Hydrostatic Test:

Sl Name & Register

Location/
Designation Date Test Result No with Remarks
chainage
No of QC Staff Page No

ii)Ultrasonic test
Name & Register
Sl Location/
Designation Date Test Result No with Remarks
No chainage
of QC Staff Page No

iii)Radiographic test
Sl Name & Register
Location/
N Designation Date Test Result No with Remarks
chainage
o of QC Staff Page No
(i)
a)
b)
(ii)
a)

6) Remarks/ Other observations, if any ...........

7)Certified that the of tests are conducted by the QC staff as per the frequency entrusted
to them

AEE/QC&I DEE/QC&I EE/QC&I

1.8 ROLE AND DUTIES OF THE DEPARTMENTAL QUALITY CONTROL FIELD

STAFF
➢ The Quality Control AEE/ AE and DEE are responsible only for the dimensions
verified by them in the Quality Evaluation sheet and Measurement Book.
➢ Minimum of 25 % of external dimensions of superstructure recorded in the M.B
are to be verified by the Q.C AEE/AE.
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 ➢ Minimum of 10 % of external dimensions of superstructure recorded in the M.B
are to be verified by the Q.C DEE.
➢ Q.C AEE /AE shall invariably conduct 10% of the tests specified as per
approved norms and relevant I.S Codes.
➢ Q.C DEE shall invariably conduct 3% of the tests specified as per approved
norms and relevant I.S Codes.
➢ Q.C EE shall invariably conduct 1% of the tests specified as per approved norms
and relevant I.S Codes.
➢ Q.C Executive Engineer shall be responsible for ensuring filling of Quality
Evaluation Sheet by AEE/AE , DEE and himself.
➢ The above mentioned number of tests/checks have to be conducted for all the
works costing more than Rs.2 Crores of agreement value.
➢ Quality verification Report shall include possible tests to be conducted and

dimensional checks as specified above at each stage of work under consideration

(i,e 1/3, 2/3 and final stage). The Executive Engineer QC shall be responsible for

such report and also shall be responsible for physical presence of the items

costing more than 5% of agreement value.

1.9 CONFIGURATION OF QUALITY MANAGEMENT SYSTEM

QUALITY MANAGEMENT SYSTEM

Quality planning, Q.C. Quality Assurance Quality Control Quality Audit

Manual; Training of
Q.C /Q.A. Staff,
Infrastructure etc. Quality
Improvement

1.10 QUALITY CONTROL (Q.C.)

Quality Control is the operational techniques and activities that are used to fulfill the
requirements of quality in end product.

The construction staff and Quality Control staff shall be well acquainted with the
Quality Control procedures and tests to be done before, during and after the work. They have
to be imparted periodical Quality Control trainings for effective Quality Control.

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1.11 QUALITY ASSURANCE (Q.A.)

Quality Assurance in construction activity relates to proper design, use of adequate

materials and components to be supplied by the contractor, proper workmanship in the
execution of works and ultimately by proper care during the use of work/structure including
timely maintenance and repair.

All the planned and systematic activities implemented within the quality system and
demonstrated as needed to provide adequate confidence that an entity will fulfill requirements
for quality; and making sure that the quality of a product is what it should be.

Purpose of Quality Assurance is to prevent problems before they occur to identify and
correct them swiftly if they occur, and to uncover the root cause.

Quality Control and Quality Assurance is carried out on, ongoing and Completed
works with respect to compliance with all Contractual Specification, Codes, Standards and
Government Regulations Such as Government Standard Specifications (SS) and IS Codes.

Before starting the work the various steps involved in the execution of work shall
thoroughly be discussed by the construction staff and agency staff in the presence of Quality
Control staff.

The work related drawings, Hydraulic particulars and other required information shall
be got approved by the competent authority before starting the work and accordingly it shall
be adopted in Quality Assurance. The construction staff shall prepare a comprehensive plan
to be adopted for a work which shall involve all steps to be followed during the work and the
same shall be got approved by the Quality Control staff.

1.12 QUALITY MANAGEMENT:

All activities of the overall management function that determine the quality policy,
objectives and responsibilities, and implement them by means such as Quality Planning,
Quality Control, Quality Assurance, and Quality Improvement within the quality system.

During execution of work, the construction staff have to check the implementation of
the Quality Assurance plan by the agency which was approved before the grounding of the
work. The agency personnel have to strictly adhere to the Quality Assurance plan and shall
conduct the required Quality Control tests along with the construction staff.

24
 The Quality Control staff shall periodically inspect the work and conduct the required
tests on the work. The deficiency found if any pertaining to Quality Control shall be brought
to the notice of agency and construction staff for its rectification.

THE QUALITY CONTROL MANUAL being adopted for All irrigation Projects (the
salient requirements of which are being outlined in the various Chapters) aims at a "Systems
Approach" to ensure that upon implementation, the quality levels as set and defined in the
specification and contract documents and relevant Indian Standards would be met in the
execution of project works.

In case, due to changes in codal provisions during course of execution, if the

acceptance criteria of tests gets changed, the contractor has to follow the revised criteria of
acceptance. In case of discrepancy in the standards/procedures of testing of this manual and
agreement specifications etc, the decision of the Engineer-in-Charge/Project Authority is
final.

25
 CHAPTER – II

ORGANISATIONAL SETUP

2.0 GENERAL

i. Anyone connected with quality control work, should possess adequate knowledge and
experience of quality control works and be conversant with general testing of construction
materials. The object of Quality control should be clearly understood by them in letter
and spirit so as to help in construction and achieve high order of quality as laid down in
specifications for works by controlling various factors responsible for deterioration in
quality, investigating reasons therefore and suggesting ways and means for improvement
and not to hinder the progress.

ii. To have proper control and avoid any type of pressurization, quality control Formation
shall consist of an independent Wing, headed by the Chief Engineer vested with full
powers of Chief Engineer. The Quality Control wing will have Quality control &
Inspection Circles headed by Superintending Engineers. A Quality Control circle shall
have quality control divisions, each headed by an Executive Engineer. Thus in the
Irrigation & CAD department, there will be separate streams for construction and quality
control assurance respectively upto the focal level of Chief Engineer beyond which there
will be a common head viz., Engineer- in- Chief (I). The Chief Engineer in charge of Q.C.
& Q.A. shall have a role of complimentary to that of the Chief Engineer of construction.

iii. Every Divisional jurisdiction shall be divided into no. of sub-divisions and each sub
division is to be put under the charge of one Deputy Executive Engineer for the purpose
of effective quality control. Each sub-division in turn shall be further sub-divided into
smaller sections. Each section shall remain under the charge of Assistant
Engineer/Assistant Executive Engineer. The Executive Engineer, Quality Control, to
avoid over lapping, shall make all these arrangements demarking the areas of operation
of every quality control staff and issue a duty chart for each staff member. Field
laboratory will be located at a convenient nodal point of jurisdiction of the Division
depending upon the quantum of work.

iv. Each Quality Control sub-division headed by the Deputy Executive Engineer entrusted
with quality control work, shall be provided with one or more mobile laboratories
tagged on with quality control units and sub units, where facilities for conducting field
26
 tests, as may be necessary shall exist. Functions of Central, Field and Mobile
laboratories are enumerated in Chapter III.

v. One of the fundamental principles to be understood and kept in mind is that the overall
responsibility for achieving construction quality in each project rests with the line of
department of the concerned project Chief Engineer. The Construction staff shall not be
absolved of any deficient or bad quality construction.

27
 CHAPTER – III

GENERAL FUNCTIONS OF LABORATORIES

The Laboratory system, in addition to evaluate and monitor the inputs and outputs
would also evaluate and monitor the workmanship as well as construction plant, machinery
and equipment. This would thus, be accompanied by testing as well as inspection.

3.0 FUNCTIONS OF CENTRAL LABORATORY (LEVEL II)

i) To conduct laboratory tests on samples of sand, coarse aggregate, stone, cement

and steel for use in masonry and concrete works. .

ii) To conduct laboratory tests for foundation soil and for selection of soils from
proposed borrow areas, for use in the various zones of embankment as per
specifications

iii) For masonry and concrete, the strength of mortar and concrete has to be as specified
in agreement. Laboratory has to design the proportions of different ingredients
through tests for the specified strength. The proportioning shall be done by weight.

iv) For Concrete and mortars where strength is not given and only proportions have been
specified, the strength should be treated as standard for execution.

v) When controlled concrete is specified, it is essential that mix design is to be done.

vi) Since the strength of cement varies from batch to batch in a cement factory itself, it is
essential that a relation between strength of cement versus strength of concrete may
be worked out in the lab, well in advance of the starting of the work. This would
facilitate in furnishing the proper proportion of the mix to the field and also it entails
adding or reducing cement content based on the strength of the cement.

vii) The strength of concrete is specified for 28 days. It will be difficult to wait for 28 days
to get the strength of concrete and assess its quality. Hence accelerated curing test be
undertaken as per the relevant I.S. using boiling water method. From this method, a
relationship between strength attained using accelerated curing method versus normal
curing method at 28 days may be arrived at.

28
 viii) Results of tests performed in the central laboratory should be reported in the
prescribed proforma pertaining to the following tests.

A. SOILS:

Disturbed grain size analysis I.S. 2720 part (IV) 1985.

Proctors compaction I.S. 2720 (Part VII & VIII)

Atterberg's limit I.S. 2720 (Part V) 1985.

Permeability I.S. 2720 (XVII). 1986 (at OMC. MDD)

Shear test (remoulded at OMC.MDD Drained/undrained) I.S.2720 (Part XIII) 1986.

Specific gravity I.S. 2720 (Part III) 1980. Undisturbed density and natural moisture
content, permeability, consolidation, shear test (drained/undrained) at NMC or
saturation.

Free swell index; Swelling pressure of soil sample.

Dispersibility of soils.
Total Soluble salts.
Chemical test for carbonates & sulphates (Chlorides Gypsum test).

B. SAND:

For IS: 383-1970 Grading, IS: 2386 (Part I) Fineness Modulus, IS: 2386 (Part III)
Bulkage , IS: 2386 (Part II) Organic and silt content.
Deleterious material and mica content, and presence of organic impurities, if any.
C. CNS:

Requirement should broadly conform to I.S. 9451-1994(Reaffirmed 2004)

D. CEMENT:

Consistency, specific gravity, compressive strength, setting time, soundness by

Le-Chetlier test.

E. COARSE AGGREGATE:

Grading I.S. 2386 (Part I) 1963.

Soundness, crushing value, impact test.

Abrasion, Absorption, I.S. 2386 (III) 1963. Specific gravity I.S. 2386 (Part III) 1963
Flakiness.

29
F. BOULDERS:

Soundness, weight and size, absorption, specific gravity, weathering conditions

(visual) abrasion after breaking to proper sizes.

G. FILTER MATERIALS:

Grading, uniformity Co-efficient, weathering conditions (visual) and tests for fine and
coarse aggregate.

H. WATER:

P.H. Value, silt content, soluble salts.

I. HARDENED CONCRETE AND MORTARS:

Proportion by chemical analysis and compressive strength.

J. BRICKS:

Dimensions and physical properties including compressive strength.

K. TESTS FOR FOUNDATION INVESTIGATION AND INSITU PERMEABILITY:

Other properties, if tested shall be reported in the remarks column or foot note.

L. LDPE Film wherever used shall be tested (IS 3395 – 1997)

PVC water stopper wherever used shall be tested as per IS 15058 - 2002

M. IMPROVED DEVICES FOR QUALITY CONTROL:

It is planned to introduce improved devices for achieving speedy and efficient quality
control. Monitoring the characteristics of fresh concrete is important from the point of view
of quality control. The 28 - day strength of concrete is the criteria for acceptance and is the
basis of quality evaluation. However, one has to wait for 28 days to get the results of
compressive strength of concrete cubes/cylinders. Even the accelerated compressive strength
tests take considerable time.
The portable electronic devices, commercially available now, have made it possible
for rapid on-site measurements of slump, temperature, water-cement ratio (the most
important factor influencing the strength of concrete) and the likely 28- day strength of fresh
concrete mixes. Software supplied with the electronic unit also produces 'quality control
certificates' based on the measurements taken by this unit. This evidence of the properties of

30
concrete gives the site QC/QA Engineer, the confidence to accept or, if necessary, to reject
the concrete mix before it is placed.

Each central laboratory (Level II) is planned to be equipped with such a portable
electronic unit with software.

3.1 FUNCTIONS OF FIELD LABORATORY LEVEL III

i) To carry out routine daily tests of soils and filter material, ingredients of concrete of
the sample collected by the construction staff such as sieve analysis moisture content,
needle density tests, compaction efficiency, field density test etc., and to take samples
from compacted fill from different zones of the embankment.

ii) To carry out routine daily tests, like silt test of fine aggregates, F.M. Sieve analysis,
bulkage of fine aggregates. Absorption, specific gravity and grade analysis, surface
moisture content tests on coarse aggregates. Slump test of concrete and mortar and
collect samples of concrete and mortar in moulds as per approved frequency.

iii) To report results of tests performed in the field laboratories in the prescribed
proformae pertaining to the following tests.

A. SOILS:
1. Density, Moisture content and compaction efficiency.
2. Needle penetration.
3. Proctors density and OMC.
4. Sieve analysis.
B. CNS:
1. Gradation analysis, Atterberg Limits
2. Shear Parameters.
3. Index properties.
C. SAND:
1. Presence of deleterious materials.
2. Grade Analysis and Fineness Modulus
3. Bulkage.
D. COARSE AGGREGATE:
1. Grading
2. Physical Properties
E. FRESH CONCRETE AND MORTAR:
1. Water Cement ratio.

31
 2. Workability by slump test/flow table test.

F. BOULDER SAMPLE:
1. Absorption
2. Dimensions
3. Visual observation as regards weathering etc.
G. CEMENT:
Setting time by Vicat needle test.
H. BRICKS:

All tests for physical properties except strength which will be conducted at central
laboratory.

All other tests will be conducted in central Laboratory for which samples shall be sent
by the field laboratory to central laboratory.

iv) The field laboratories will report the testing data in the prescribed forms meant for
soil, concrete masonry, filter and boulder pitching work, lining etc.

3.2 FUNCTIONS OF MOBILE LABORATORY (FIELD TESTS)

i. To carry out daily routine tests on compaction efficiency. Field density and field
moisture content determination test.
ii. To carryout daily routine tests like silt content, fineness modulus and gradation of
fine aggregates and coarse aggregates.
iii. To carry out slump test, unit weight and Temperatures of concrete by using fresh
concrete insitu testing equipment, and to take fresh concrete samples as per the
required frequency.
Note: Scope and inspection of testing activities are illustrated in Annexure II

32
 CHAPTER – IV

DUTIES OF STAFF INCHARGE OF LABORATORIES

4.0 DUTIES OF DEPUTY EXECUTIVE ENGINEERS AND OTHERS INCHARGE

OF LABORATORY

i. To ensure proper up-keep and maintenance of laboratory equipment in laboratory.

ii. To ensure proper maintenance of records of all samples being tested in the laboratory
as per prescribed forms and Communication to the concerned.

iii. To supervise the testing works of Assistant Engineer / Assistant Executive Engineers,
laboratory Assistants and personally to check the tests to the extent of 25 %.
iv. To prepare fortnightly review of all the test results and submits to the Executive
Engineer, Quality Control.
v. To conduct any research work as may be assigned by the Executive Engineer.
vi. Steel rods as proposed to be used shall be tested for ultimate tensile strength
elongation and bond etc., as per standards.
vii. Samples of welded rods, welded at site shall be collected and tested to the quality of
welding.
viii. The Central Laboratory has to conduct the test on the suitability of materials proposed
from various quarries of work, well in advance of the actual execution of work, for
which the construction staff shall send the material to the lab well in advance.

4.1 DUTIES OF ASSISTANT ENGINEERS / ASSISTANT EXECUTIVE

ENGINEERS (LABORATORY)

Shall perform important tests as mentioned below:

A) CEMENT:

1. Fineness by Blains
2. Normal Consistency
3. Setting time
4. Soundness
5. Specific gravity
6. Compressive strength
7. Adulteration test

33
B) SAND

1. Sieve Analysis & Fineness modulus

2. Test for organic impurities silt & clay
3. Decantation test for silt
4. Specific gravity
5. Unit weight and bulkage factor

C) COARSE AGGREGATE :

1. Sieve Analysis and gradation

2. Specific gravity
3. Water absorption
4. Examination of deleterious materials
5. Crushing strength
6. Impact
7. Abrasion
8. Flakiness index
9. Alkali - Silicate reactivity

D) CONCRETE:
1. Consistency - slump or compaction factor
2. Compressive strength
3. Air content
4. Yield per unit quantity of cement.
5. Mix design test
6. Cement content

E) MORTAR:

1. Consistency
2. Compressive Strength
3. Yield per unit quantity of cement
4. Cement Content

F) SOILS:

1. Gradation (Grain size analysis)

2. Consistency limits
3. Porosity & Void ratio
4. Specific gravity
5. Swell pressure

34
4.2. DUTIES OF LABORATORY TECHNICIANS / WORK INSPECTORS

i) To assist Assistant Engineers/Assistant Executive Engineers whenever required in

laboratory and field work.

ii) To perform tests in laboratory such as:

a) Compaction tests
b) Limit tests
c) Analysis of fine & coarse aggregates
d) Silt in fine aggregate
e) Slump test
f) Collection of samples of concrete and mortars for filling moulds for
compaction test.

4.3 DUTIES OF LABORATORY ATTENDANTS

a) To keep instruments clean.

b) To assist Assistant Engineers / Assistant Executive Engineer and Laboratory
Technicians in conducting tests.
c) To prepare samples for test.
d) To arrange samples systematically.

4.4 CONTROL OF INSPECTION, TESTING AND MEASURING EQUIPMENT:

The identification, calibration, and adjustment of all inspection, measuring and test
equipment and devices will be done at prescribed intervals as stated below against certified
equipment having a known valid relationship to nationally recognized standards. The
equipment will be capable of controlling the delivery of material for weighing so that
inaccuracies in feeding and measuring during normal operation will not exceed 1% for water
and 3% for all aggregates. Periodical test will be made at least once in 2 weeks in case of
equipment for measuring water, cement, and admixtures and at least once in every month in
case of equipment measuring sand and coarse aggregate. Other measuring equipments will be
tested once in a year unless some defects are noticed earlier, in which case these will be
attended immediately. Documents will be established and calibration procedures will be
maintained including details of the following:-

1. Equipment type 2. Identification number

3. Location 4. Frequency of Checks
5. Check method 6. Acceptance criteria.

7. Action to be taken for unsatisfactory results, to ensure that the inspection,

measuring, and test equipment are capable of the required accuracy and precision.

35
 CHAPTER – V

DUTIES OF FIELD STAFF IN RELATION TO QUALITY OF WORKS

5.0 DUTIES OF ASSISTANT EXECUTIVE ENGINEER

ASSISTANT EXECUTIVE ENGINEER/ ASSISTANT EXECUTIVE ENGNEER/

ASSISTANT ENGINEER CONSTRUCTION ASSISTANT ENGINEER QUALITY
CONTROL
1. Shall see that the markout of the area to be 1. Shall check the markout foundation/
tackled is properly given, shuttering, prelevels and centering/shuttering
centering, reinforcement are done as per reinforcement arrangements and inform
drawings and technical specifications, to the Assistant Executive Engineer /
record the Pre levels/foundation levels, and Assistant Engineer construction to rectify
to see that mark-out for canal excavation is the defects if any. Shall certify the
perfectly given as per drawings. Prelevels, markout of canal excavation as per
classification levels and final levels of canal drawings. Prelevels, classification levels
shall be taken as per specification and got and final levels of canal shall be checked.
verified by Quality Control Assistant
Engineer/Assistant Executive Engineer.

2. Shall see that the construction equipment 2. Shall check the adequacy of the
like mixers, vibrators, rollers, pumping construction equipment and curing /
arrangements for water curing/curing watering arrangements.
compound are arranged before starting of
any work.
3. Shall conduct the field tests on input
3. Shall see that sufficient quantities and materials and record the results and to
quality of input materials as per agreement inform the Assistant Executive
specifications are made available at site of Engineer/Assistant Engineer construction
work and to arrange testing equipment, men to rectify the defects if any. To send the
and material required for conducting field samples of input materials to central lab as
tests on input materials or for sending and when required. To conduct core tests
samples of input materials to central lab. and other field tests as per IS codes in case
of Embankment works.

4. Shall write O.K. Cards after area is ready to 4. Shall check and write the O.K. card and
start the work and to inform the Asst. record the deviations, defects if any or
Executive Engineer /Assistant Engineer otherwise to record the final OK and to
Quality Control and Deputy Executive inform the Deputy Executive
Engineer construction and take permission to Engineer/Executive Engineer quality
start the work on O.K. Card. control and to permit to start the work.

5. Shall supervise and ensure that correct 5. Shall make constant checks of the feeding
quality and quantities of input materials as
per mix design communicated by the central

36
 laboratory are fed into the mixers/batching of input materials mixing time and suggest
plants etc., and shall ensure adequate mixing
the quantity of water depending on the
time
moisture content of sand as and when

6. Shall ensure proper vibration, rolling etc.. required.

during course of day to day work and to
provide men and material required for 6. Shall conduct slump test, record
extracting samples of finished product for temperature of concrete, core tests, proctor
quality control staff. of concrete, proctor density etc., and to
extract field samples of finished product to
7. Shall ensure proper curing of samples be sent to central laboratory later.
extracted till the curing time is over and to
make arrangements to send the samples to 7. Shall assist the Assistant Engineer /
central lab. Assistant Executive Engineer Construction
in Proper handling/ transport of samples to
8. Shall ensure timely green cutting of concrete central lab.
with proper air - water gun: nicking &
chipping (wherever so warranted) so as to 8. Shall check and see that the preparation of
prepare the surface for next concrete lift for the surface is adequately done for starting
effective bend at the lift/construction joints. the next lift.
9. Shall ensure proper curing/watering and
allow removal of centering only after the
time limit prescribed in the specifications 9. Shall check the adequacy of curing /
and to see that the surfaces are finished to watering and see that the final surfaces are
the plumb/straight lines etc., after removal of finished neatly plumb/straight lines etc.
shuttering.

10. Shall maintain (1) mark-out register (2) OK

Card files (3) Load Register.
10. Shall maintain registers of field tests
conducted.

The AEE.s/A.Es working at tunnel both in construction and Q.C. staff shall pay special
attention on

1. Marking / checking the center line after every head blasting & mucking.
2. Monitoring oxygen and carbonmonoxide levels in the tunnel as well as
lighting.
3. Checking the alignment of concrete placement Gantry.
4. Monitoring Safety measures.

37
5.1 DUTIES OF DEPUTY EXECUTIVE ENGINEER

DEPUTY EXECUTIVE ENGINEER DEPUTY EXECUTIVE ENGINEER

(CONSTRUCTION) (QUALITY CONTROL)
1. Shall exercise proper check over all the 1. Shall exercise proper check over all the
activities of Assistant Engineer /
activities of Assistant Engineer / Assistant
Assistant Executive Engineer/ Quality
Executive Engineer, Construction. Control.

2. Shall verify the foundation/ pre-levels, 2. He shall invariably check foundations

check the mark-out, reinforcement of all components of works. Final OK
centering etc., invariably for all works. is to be recorded before the work is
started. Where heavy reinforcement is
involved the same also should be
checked invariably and final OK is to
be recorded.

3. Shall check feeding of input materials, 3. Shall check at random feeding of input
mixing, placing, vibration rolling etc. materials, mixing, placing, vibration
rolling etc.

4. To ensure that the cement used at site of 4. Shall check the test reports of cement,
work is tested in the central laboratory. date of manufacture etc., and satisfy
before starting of the work.

5. Shall write the OK cards after satisfying 5. Shall write O.K. cards as and when
about the arrangements made for starting of required and inform the Executive
the work and report to the Executive Engineer/Quality Control accordingly.
Engineer/ Construction. Executive
Engineer / quality control accordingly.

6. Shall see that samples of finished products 6. Shall conduct the field tests like slump,
are transported to the central laboratory. temperature of concrete at random.

7. Shall personally supervise the rectifications 7. Shall intimate the defects if any to
pointed out by Executive Engineer the Executive Engineer Construction
Construction, Executive Engineer Quality and Executive Engineer Quality
Control. Control, Check and verify whether
rectifications are done as per the norms
laid down in the contract
specifications.

8. Should arrange to get the foundations of 8. Shall assist the Deputy executive
soil tested in case of weak soil over which Engineer Construction in conducting
heavy Embankments are proposed. these tests.
9. He should send soil samples in various 9. Shall assist the Deputy Executive
reaches well in advance to central Engineer Construction in sending the

38
 laboratory and get the soil tested for samples to central laboratory.
various properties and obtain OMC and
MDD values.
10. Shall order temporary suspension of work 10. Shall order temporary suspension of
if any serious defects are noticed and shall work if any serious defects are noticed
intimate immediately to Executive and shall intimate immediately to
Engineer Construction and Executive Executive Engineer Construction and
Engineer quality Control. Executive Engineer Quality Control.

5.2 DUTIES OF EXECUTIVE ENGINEER

EXECUTIVE ENGINEER EXECUTIVE ENGINEER QUALITY

CONSTRUCTION CONTROL
1. Shall supervise, check, advise, and instruct 1. Shall supervise, check, advise and instruct
the A.E/A.EE/ D.EE Construction the A.E/A.E/D.EE Quality control
regarding discharge of their functions regarding discharge of their functions
properly. properly.

2. Shall intimate the Executive Engineer 2. Shall maintain copies of approved

quality control regarding signing of Designs, reports, contract document,
agreement for starting of any new work, drawings, construction programme,
duly endorsing a copy of work order. Shall extracts of inspection notes etc., and shall
supply copies of contract documents, see that his subordinates go through
drawings Construction programme etc., to the above documents.
Executive Engineer Quality Control. and
Superintending Engineer Designs and
Inspection Circle.

3. Shall see that all ingredients of concrete, 3. Shall remind, ensure and verify whether
masonry are got tested before use. Shall test results are available or not before
see that the soils are tested for various starting up of any new work.
properties like OMC, MDD. etc. before
starting of Embankment work.

4. Shall see that all the Machinery/ 4. Shall assist in upkeep and calibration of
equipment being used by the contractor equipment.
is got periodically calibrated
5. Shall inspect and sign on O.K. Cards
5. Shall see that OK Cards are written and during field visits.
kept at site of work before starting of any
work.
6. Shall order the suspension of work if any
6. Shall order the suspension of work if any defects are noticed or reported by quality
defects are noticed or reported by quality control staff and intimate his counterpart
control staff and resume the work only to see that defects are rectified. If not
after rectification of defects in the rectified the matter is to be reported to the
presence of quality control staff. S.E./Quality Control.

39
7. Foundations and reinforcement, shuttering,
centering where heavy reinforcement is 7. Foundations and reinforcement,
involved is to be checked by Executive shuttering, centering where heavy
Engineer invariably before starting the reinforcement is involved is to be checked
work.. by Executive Engineer invariably before
starting the work.
8. Shall jointly inspect the site with quality
control Executive Engineer in case 8. Shall jointly inspect the site with
variation in classification is less than 10% Construction Executive Engineer in case
(+/-) and finalise the classification. variation in classification is less than 10%
(+/-) and finalise the classification.

9. Shall personally see that the samples

proposed to be sent to the laboratories like 9. Shall pursue and keep track of sending of
T.S.E.R.L/N.C.C.B. are sent regularly as samples to T.S.E.R.L/N.C.C.B. and to
per the need, obtain the results and keep record of results received.
communicate the same to Executive
Engineer, Quality Control.

10. Shall take the help of quality control

Executive Engineer whenever a dispute is 10. Shall co-ordinate with the
referred to Technical Expert. EE/Construction division render
assistance in resolving the issues referred
to technical expert.

40
 CHAPTER - VI

CO-ORDINATIONS

The construction staff and quality control staff must act in tandem as a single unit to
achieve good quality of the finished product and construction as per the contract
specifications.

Construction staff should make it a point to inform the quality control staff, the date
of starting of any component of the work well in advance so as the enable the quality control
staff to schedule their work plan and attend the particular work on that particular date.

In turn quality control staff should programme their itinerary, so as to attend the work
on the dates required by the construction staff and ensure that, the progress of work is not
hampered.

The Construction staff shall be responsible for exercising the various field checks
with reference to drawing and specifications laid down in respective I.S. code during
construction and carrying out all the laboratory and field tests on materials used for
construction and reporting through their higher officer, to the field staff for ensuring quality.

The agency shall be made responsible to provide equipment for all the field tests to be
conducted on the work. The equipment has to be made invariably available for all the testing
of Q.C. and construction wings.

The Defects, if any, noticed by the quality control staff during their course of
inspection shall be brought to the notice of the construction staff then and there. It is the
primary responsibility of the Quality Control & Inspections staff to draw the attention of the
construction staff, whenever they notice defective work during their course of inspection. It is
the duty of the construction staff to attend to the rectification and maintain proper
specifications as pointed out by their counter part of the Quality Control organization.

As far as possible the defects are to be rectified in the presence of the Quality Control
staff and the payment shall be effected only after the Quality Control staff have fully
satisfied with the rectification and quality of work. Any rectification done subsequently
without any intimation and presence of Quality Control staff shall be at the sole responsibility
of the construction staff.

41
 The quality control staff cannot supervise the placement of concrete on a mix to mix
basis continuously. They can only conduct random check of input materials, mixing time,
placement of concrete, vibration etc. It is the primary responsibility of the construction staff
to ensure adequate supervision of mix to mix placement of concrete.

The Operations of the Quality Control Staff shall not interfere in any way, with the
executive powers vested with the officer’s incharge of execution. They will also in no way
diminish the responsibility of the officer’s incharge of execution. The field officers incharge
of works are primarily responsible for the quality of all works and to carry out the work as
per the technical specifications.

In case of difference of opinion between quality control staff and construction staff, it
should be sorted out by way of discussions in cordial atmosphere and mutual trust as per the
guide lines indicated below. In case it involves any design feature/problem/aspect, the design
office should be duly consulted and the advice given by the designer should be accepted.

Where the objection raised by the Assistant Engineer/ Assistant Executive Engineers;
of quality control is not acceptable to his counterpart by the construction unit, the Deputy
Executive Engineer of construction shall discuss with his counterpart of quality control to
settle the objection. If they fail to arrive at a solution, the matter may be reported to the
Executive Engineer/Construction who would discuss the issue with the Executive Engineer,
Quality Control. In case Executive Engineer, Quality Control is not readily available at site,
the Executive Engineer, Construction may take suitable decision and intimate the Executive
Engineer, Quality Control and Superintending Engineer, Construction of the decision taken
with reasons.

In case of difference of opinion between Executive Engineer, Construction and

Executive Engineer, Quality Control, it would be referred to Superintending Engineer,
Construction, who would discuss the matter with Superintending Engineer, Quality Control
and settle the issue. Similarly, when the Superintending Engineer, Quality control is not
readily available, the Superintending Engineer, Construction can overrule after recording the
reasons in writing. In such cases the Superintending Engineer, Construction has to discuss
with Superintending Engineer, Quality Control at the earliest opportunity and modify his
earlier orders, if necessary.

In case there is a difference of opinion between both Superintending Engineers,

Construction and Quality Control the matter would be referred to Chief Engineer whose

42
decision shall be final and binding on all. Work should immediately be suspended and not
allowed to resume until the defects pointed out by Quality Control and Inspection staff are
rectified. Disciplinary action shall be taken against the construction staff concerned who
frequently violate this rule and appropriate measures taken against the contractor to rectify
unacceptable work at contractor's cost.

The construction and quality control staff shall keep a regular liason with the
Geologist in respect of all Geotechnical problems and enlist his input on foundations of
structures & dams, Cut off Trenches, tunneling, contract/consolidation/curtain grouting,
Rock/Excavation Slopes (stability of slopes), protection measures, permeability/Water loss
tests etc., as well as any geological problem. The advice rendered by the Geologist should be
discussed with the Designers and duly respected and implemented.

43
 CHAPTER – VII

QUALITY ASSURANCE AND INTERNAL QUALITY AUDIT

7.0 QUALITY ASSURANCE:

All planned and systematic strategies and actions necessary to generate adequate
confidence that Input and Output product will satisfy given requirements of quality and all
the components of works perform satisfactorily during life period of service, adequate quality
checks as analyzed during construction is a record which speaks of "Quality Assurance". It
comprises planning and policies, education and training standards and specifications,
contracts and agreements, and quality control. Quality assurance is to assume that the
materials as per standard and as per the requirements have gone into the production of
concrete, earth, masonry work etc. This is achieved by evaluating the quality checks during
construction and post construction tests made and compared.

7.1 QUALITY AUDIT:

It is a systematic and independent examination to determine whether quality activities

and related results comply with planned arrangements and whether these arrangements are
implemented effectively and are suitable to achieve the objectives. It is considered to be an
effective management tool to promote good quality construction and workmanship.

It will be expedient and useful to present the requisite of Quality Assurance to the
Quality Audit team in as concise format as possible. Control charts are one such presentation.
Visual displays on these charts greatly enhance the communication of information.
Accordingly, Control charts for all critical tests including the following should be prepared
and presented to the quality Audit Team:

• Test strength of cement.

• Test strength of concrete.
• Slump Test.
• Concrete Temperature.
• Air Content.
• Aggregate gradation.
• Field moisture and density test results.

44
 Quality Audit: The Scope of Quality Audit is limited to post construction and
verification in the following manner.
1. Evaluation
2. Compliance
7.1.1 EVALUATION
It shall broadly cover the following aspects
i) Evaluation of testing inspection efficiency from the standpoint of such matter as :
a) Effectiveness of procedures.
b) Operational efficiency of plant and equipment.
c) Adequacy of personnel.
d) Programme records.
ii) Evaluation of internal control from the stand point of Quality Control / Quality Audit
System provides for.
a) Information that is Adequate Accurate.
b) Effectiveness of Communication and feedback of quality control decisions to
the operational level.
c) Control over all phases of operation.
iii) Evaluation of overall performance of various project laboratories from the Standpoint
of:
a) Procedures being followed.
b) Performance of individual laboratories.
c) Inter laboratory testing.

7.1.2 COMPLIANCE
Procedures and controls are of no significance unless those are meticulously followed
in practice. Quality Audit shall Endeavour to ascertain whether or not the planned programme
is actually being carried out in practice. The technique of ascertaining this shall be through:
a) Inspection and visual observation of work to Audit the quality of output.
b) Examination of O.K. Cards
c) Examination of test records and reports of various inputs.
d) Perusal of control charts for cement and concrete.
The quality Audit shall also make a broad review of the activities of each laboratory
and the associated quality control group in order to determine whether the functions and
responsibilities assigned to them are being performed in a satisfactory manner to determine:

45
a) Whether the testing and inspection personnel have adequate understanding of
testing procedure.
b) Whether the testing and inspection carried out are adequate.
c) Whether adequate corrective actions are being taken to prevent the use of
defective materials or workmanship.
d) Whether the records and reports of testing and inspection maintained are adequate
and complete.
e) Whether these records are checked by the senior officers at regular intervals.

7.1.3 LIST OF DOCUMENTS '

Each laboratory should hold the following documents :

• Quality control manual.

• Technical Records: Specification. Contract documents. Inspection and Test
Procedures, relevant standards/Codes of practice.
• Mill Certificates. (MTC)
• Corrective action records.
• Material test reports, test reports of cores
• Inspection Reports.
• Photographic/Video film records of construction which may not remain
accessible after commissioning of the project.
• Non-conformance reports.
• Statistical evaluation reports.
• Technical Literature.
• Standardization of records

7.1.4 QUALITY CONTROL PERSONNEL SHOULD HOLD THE FOLLOWING

DOCUMENTS

• Data of test.
• Area where material is used.
• Test method with reference to Standards.
• Testing results, including those of cores of concrete.
• Acceptance criteria.

• Statement of compliance/non-compliance.

46
• Remarks.
• Test Personnel signature.
AEE/AE should always have a kit consisting of equipment i.e., measuring tape,
scale, vernier calipers, plumb rule and bob, square, hammer, and measuring glass etc. to
facilitate for checking quality of work in the field.

Presentation to QUALITY AUDIT Team

To have uniformity in presentation, it will be good to standardize:

Forms for testing of material.

Inspection "Check items".
O.K. Cards.

47
 CHAPTER – VIII

O.K. CARDS

8.0 GENERAL

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

stages and are liable to be referred/perused at a later stage also, particularly during the
Internal Quality Audit of works, the O.K. Cards shall be maintained in duplicate in two
colors. The green colored card shall form a part of the record of Q.C./A.Q. Wing and the red
colored card remains in the custody of construction Wing. The O.K. Cards, relating to any
particular work, shall be put in a round shaped tin box and placed right at the construction
site. The exterior of the tin box shall be painted red. After the particular work has been
completed (say, concrete placement has been completed in a particular lift: likewise say, fill
placement has been completed in a particular layer etc., etc.), the two O.K. Cards shall be
removed from the tin box and filed in the permanent record files of the construction and
Q.C./Q.A. Divisions respectively. Senior officers shall also check the O.K. Cards during
their field inspections to ensure that those are being maintained and properly/genuinely filled.

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

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

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

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

The Assistant Executive Engineer (Construction) will prepare two copies of O.K.
Cards by filling in the first set of columns meant for the construction staff and hand over to
the Assistant Executive Engineer (Quality Control) in charge of the Quality Control Unit. The
quality control staff at actual work site shall check the requirement or shall perform necessary

48
 tests under the guidance of Assistant Executive Engineer, Quality Control. The Assistant
Executive Engineer, Quality Control will scrutinize the O.K. Cad and finally Okay the work
if anything otherwise is not observed. Should anything otherwise be found, the O.K. Card
shall not be signed by him and ask the Assistant Executive Engineer (Construction) for
necessary rectification.

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

It must be borne in mind that work cannot be held up unduly for disposal of O.K.
Card. The Executive Engineer/Deputy Executive Engineer (Quality Control) will be the
okaying authority for concentrated work like dam, spillway and Barrage and important
structures and the Assistant Engineer/Assistant Executive Engineer Quality Control will be
the okaying authority for scattered works like canals and small structure. Random checks by
Superior officers should be recorded on O.K. Cards at site.

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

Specimen of O.K. Cards for various works such as embankment, concrete, masonry.
Grouting and Tunneling etc., have been enclosed below.

O.K. CARD FOR EARTH WORK EMBANKMENT

GOTS GOTS
S. No. Description Contractor Remarks
(CS) (QCS)
1. Name and location of borrow
area
Prerequisite: Benching, stripping
of base whether key trench is
made and base watering is done
2. Location of work from Km
_____ to Km _____
3. Elevation (R.L.,)
4. Surface preparation, whether as
per specification.
5. Type of roller used.

49
 6. Location of test at Km.
7. Thickness of loose layer.
8. Initial moisture content
9. Removal of over size material,
vegetation and debris etc.
10. Top level after compaction of
layer
11. Wet density
12. Moisture content in rolled fill
13. Dry density
14. Laboratory OMC and MDD
15. Compaction efficiency
16. Embankment of instruments
devices (in case of earth dam)
17. Methodology of addition of
moisture (whether through spray
from sprinkler tanker)
18. Manual compaction, if any
19. Layer passed
20. Any other remarks

Signature of Site In Signature of Construction Signature of Quality Control Staff with

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

O.K. CARD FOR SUB GRADE PREPARATION

S. No. Description Contractor GOTS GOTS Remarks

(CS) (QCS)
1. Date
2. Location
3. Whether sub-grade is prepared
as per specification in case of

50
 a) ROCK – (Over excavation)
b) Swelling soils (Treatment
with CNS soils)
c) Over excavation in soils
4. Whether the profile of canal
section is prepared to model
section.
5. Whether porous plugs are
casted as per specification.
6. Whether the work of laying the
filter media is carried out as per
approved drawing in case of
a) Porous Plugs
b) Longitudinal and transverse
drains
7. Flap valves placed as per
drawing
8. Whether sub-grade is wetted to
150 mm depth as per
specification.
9. Compaction of sub-grade
10. Methodology of compaction.
11. Methodology of moisturing,
wetting of sub-grade
12. Any other remarks

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

51
 O.K. CARD FOR CAST – INSITU CONCRETE LINING

GOTS GOTS
S. No. Description Contractor Remarks
(CS) (QCS)
1. Date
2. Location from Km _____ to
_____ Km _____ bed side slope
L/R
3. Proportion of the mix
4. Materials
a) Coarse aggregate under/over
size 40mm, 20mm & 10mm

b) Fine aggregate F.M. of sand

c) Cement make/Date of
Manufacture
d) Admixtures make/date of
mfr. And % used.
5. Method of concrete mix
a) Mix by Vol./Wt.
b) Batching plant by Vol./ Wt.
6. Transport
a) By transit mixer
7. Temperature of concrete
specified
8. Temperature of concrete as
placed
9. Slumps
a) At the batching plant
b) At the site of placement
10. Water Cement Ratio
11. Method of consolidation slip/
Mechanical vibrators/screened
vibrator
12. Whether contraction /
Construction Joints are
provided as per approved
drawings
13. Treatment of cold joint/joints
14. Curing: Water curing/curing
compound

52
 15. The quantity of curing
compound utilized in litres
16. The reflectance on curing
compound
17. Quantity of concrete laid/cu.m
and area in Sq.mts
18. Whether LDPE/HDPE sheet is
laid
19. No. of C.C. cubes casted
20. Any other remarks

Signature of Signature of Construction Staff Signature of Quality Control Staff

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

O.K. CARD FOR MASONRY WORK

GOTS GOTS
S. No. Description Contractor Remarks
(CS) (QCS)
1. Date
2. Location of work
a) Component of work (with
Elevation)
3. Specification of work
4. Cleaning of Old Layer
5. Curing of Old Layer
6. Batching of Cement Mortar
7. Materials whether available as
per
a) R.R. Stones
b) C.R. Stones
c) Bond Stones
d) Dressing of stones
e) Sand F.M.
8. Placing of Stone, hearting and

53
 thickness of joints
9. No. of C.M. Samples collected
10. Any other remarks

Signature Signature of Construction Staff with

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

O.K. CARD FOR STRUCTURAL CONCRETE WORK

GOTS GOTS
S. No. Description Contractor Remarks
(CS) (QCS)
1. Date
2. Grade of Mix
3. Location of work
a) Foundation (with elevation)
b) Super structure (with
elevation)
4. Methodology of preparation of
surface
5. Materials
a) Coarse aggregate under size/
over size graded analysis.
b) F.M. of sand
c) Cement make/date
d) Water
6. Tools and Plants
a) Form work details of
shuttering should be checked
with dimensions.
b) Mixer
c) Vibrators
7. Batching
8. Temperature of concrete
specified in technical

54
 specifications.
9. Temperature of concrete as
placed
10. SLUMP
a) Design slump
b) At the batching and mixing
plant
c) At the site of placement
11. Method of placing
12. Method of consolidation
13. Water cement ratio
14. Treatment of construction joints
15. Embedments
16. Water stopper
17. Concrete finish (Wood float
steel trowel)
18. Quantity of concrete laid
19. No. of CC Cubes cast.
20. Checking of reinforcement
21. Curing arrangements(Water/
Curing Compound)
22. If curing compound is used,
total quantity in Sq. mts.
23. Reflectance
24. Any other remarks

Signature Signature of Construction Signature of Quality Control Staff with Date

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

55
 O.K. CARD FOR GROUTING

GOTS
S. No. Description Contractor GOTS (CS) Remarks
(QCS)

GENERAL
1. R.L. and area of surface to be
grouted.
2. Classification of the rock strata if
grouting is in rock area
3. Salient features of the strata such as a
fault zone cavities fissures etc.
4. Permeability value of the strata
before grout.
GROUP
5. Pattern of Grout adopted
6. Depth and dia. of the grout hole
7. Pressure adopted for grout
8. Proportion of grouting mix
9. Intake of slurry mortar per unit area
per unit time.
10. Total Quality of Intake
11. Final permeability value of the strata
after grout.
12. Whether the grout strata is OK.

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

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

56
 O.K. CARD FOR SHOTCRETING

GOTS
S. No. Description Contractor GOTS (CS) Remarks
(QCS)

1 Date
Component of Structures Reduced

2 Level and area of surface to be

shotcreted
Methodology of Prepartion of
surface

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

4 Proportion of the shotcreting mix

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

6 Method of concrete mix

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

7 Transport
a) By transit mixer
b) By Mobile self loading/
weight-batching & mixing
and transporting

8 Temperature of concrete specified

Temperature of concrete as
9
placed

10 Slump

57
 a) Design slump
b) i. Slump at the batching
plant.
ii. Slump at the site of
placement.

11 Water Cement Ratio (0.35 to 0.5)

Curing: Water curing / curing by

12 membrane form of curing

compound.
Quality / Workman Ship of
13 shotcrete

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

15 Quantity of Shotcrete laid

16 No. of CC Cubes Casted

17 Any other remarks

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

O.K. CARD TUNNEL EXCAVATION

GOTS
S. No. Description Contractor GOTS (CS) Remarks
(QCS)

GENERAL
1. Layout Centre line
2. Scaling of Tunnel Heading

58
 3. Shot-creting (First Layer)
4. Rock bolting Anchoring
5. Drainage holes/Forepoling
6. Geo-technical mapping
7. Wire-mesh placement
8. Shot-creating (second layer)
9. Erection of steel supports
10. Backing/Back-fitting of supports
11. Marking of drill pattern
12. Ventilation
13. Lighting, Monitoring inside Air
14. Drilling blast holes
15. Loading blast holes
16. No. of drill holes. Quantity of
explosives loaded. No. of delays
17. Final O.K. for blast.

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

OK CARD FOR HYDROSTATIC TESTING

Sl.No. DESCRIPTION CONTRACTOR GOT GOT REMARKS

(CS) (QCS)

1 Date of testing

2 Location of Pipe Line from

_____km to______km

3 Elevation

4 Joint No. From_____to_____

59
 5 Length of pipe being tested from
Km.--------- to Km.-----------

6 Pipe No.

7 Joint No.

8 Number of Joints

9 Temperature

10 Test pressure

11 Gauge Pressure

12 Time (Retention Period) From--------

to ---------

13 Any other remarks

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

OK CARD FOR ULTRASONIC TESTING (UT)

Sl.No. DESCRIPTION CONTRACTOR GOT GOT REMARKS

(CS) (QCS)

1 Date of testing

2 Location of Pipe Line from _____km

to______km

3 Elevation

60
 4 Joint No. From_____to_____

5 Location of test at km

6 Pipe No.

7 Joint No.

8 Number of Joints

9 Temperature

10 Thickness of Material

11 Technique

12 Frequency

12 Exposed Time From____to _____

13 Any other remarks

Signature Signature of Construction Staff with Signature of Quality Control Staff

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

OK CARD FOR RADIOGRAPHY

Sl.No. DESCRIPTION CONTRACTOR GOT GOT REMARKS

(CS) (QCS)

1 Date of testing

2 Location of Pipe Line from

_____km to______km

3 Elevation

4 Joint No. From_____to_____

61
 5 Location of test at km

6 Pipe No.

7 Joint No.

8 Number of Joints

9 Thickness of the Material

10 Radiography Technique

11 Exposed Time From____to _____

12 Any other remarks

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

62
 CHAPTER – IX

LIST OF REGISTERS TO BE MAINTAINED AT THE SITE

1) Site Order Register and Placement Register.

2) Register of Bench marks.
3) Register for Permeability.
4) Register for Grouting/Shot crete.
5) Register of Materials, sieve analysis & Silt content for Fine Aggregate & Coarse
Aggregate.
6) Register for Concrete Slump and Temperature, compressive strength of Concrete
Specimens.
7) Register for Mix Designs and Test results for cement.
8) Register for Compaction (PD), Register for results of soil samples of borrow area
including coordinates of borrow area and lab test results.
9) Load Register at Batching Plant.

63
 CHAPTER – X

DETAILS OF TESTS TO BE CONDUCTED BEFORE THE WORK, DURING THE WORK & AFTER THE WORK & LIST OF LAB EQUIPMENT

Sl. Component of
Description of Test Equipment Requirement Purpose Acceptance Criteria Remarks
No Testing

ENGINEERING MATERIALS

IS Sieves 80mm, 60mm,

40mm, 20mm, 16.5mm,
Sieve Analysis To know the gradation As per IS: 383-1970 before & during the work
10mm, 5.6mm, 4.75mm, Lid
& Receiver and Balance
Balance, Oven, A wire To assess the suitability
Specific Gravity and
basket, Water tight of aggregate used in the As per design mix before & during the work
Water Absorption
Container data for mix design
To assess the suitability
Balance, Oven, Glass
Bulk Density of aggregate used in the __ before & during the work
Vessel
data for mix design
IS Sieves 63 mm, 50 mm,
COARSE 40mm, 31.5mm, 25mm,
1 Elongation & To assess the quality of
AGGREGATE 20mm, 16mm, 12.5mm, As per design mix before & during the work
Flakiness Index materials
10mm and 6.3mm, Length
Guage
Reactivity Container
Weighing Scales, Weights,
Alkali Aggregate
Sieves, Glass Graduates, To assess the quality of
reactivity test ( __ before & during the work
Specimen moulds, Mixing materials
Reaction Chambers)
Bowl, Tamper, trowel and
Container
Loss with Na2So4 <
Soundness ( Sodium Oven, Sieves and To assess the quality of
12% before & during the work
Sulphate Method) Containers materials
Loss with MgSo4 < 18%

64
 An Impact Testing Machine,
Cylindriacal Metal measure, Wearing surfaces <
Aggregate Impact
Tamping Rod, S Sieves- 30% before & during the work
Value
12.5 mm,10mm and 2.36 Other concrete - < 45%
mm, Balance
Wearing surfaces - <
Los Angeles Abrasion
30%
Aggregate Abrasion Testing Machine
Other concrete - < 50% before & during the work
value IS 2386 (Part-IV)-1963,
Sieves, Balance
15 Cm Dia open ended
steel cylinder with plunger
and base plate, tamping
Aggregate Crushing To assess the quality of
rod, IS Sieves-12.5 __ before & during the work
Value materials
mm,10mm and 2.36 mm,
balance , Compression
Testing Machine
Sodium Hydroxide, Glass To assess the quality of
Organic Impurities __ before & during the work
Jars materials
IS Sieves, Balance, anvil
and hammer suitable for
breaking pebbles, Hand
lens, stereoscopic To know the extent of
Petrography by
microscope and auxillary deleterious materials and __ before & during the work
animation
equipment for adequate Silt content.
petrographic examination
and identification of rocks
and minerals
container,balance and
Moisture Content
frying pan
Balance, Oven, A wire
Absorption Value basket, Water tight
Container
Potential Reactivity Digital length comparator
of Aggregate with air tight lid and rod
IS Sieves 4.75mm,1.18mm, To know the grain size As per design mix
FINE Sieve Analysis /
2 2.36mm, 600microns, and fineness modulus of Concrete.. IS:383-1970 before & during the work
AGGREGATE Fineness Modulus
300microns, 150microns, sand and silt content Masonry.. IS:2116-1965
65
 75 microns, Lid & Receiver Mortar Plaster:IS:1542-
and Balance 1960

Deleterious and Deleterious constituents

Sodium Hydroxide, Glass To assess the quality of
Organic Impurities plus silt not more than 5 before & during the work
Jars materials
Test percent
To know suitability of
Measuring Jar and Steel
Unit Weight sand and to utilize data __ before & during the work
Rod
for mix design
To know suitability of
Balance, Cylindrical Metal
Bulkage sand and to utilize data __ before & during the work
Measure and Tamping rod
for mix design
Specific Gravity and Balance, Oven, Glass To utilize data for mix
As per design mix before & during the work
Water Absorption Vessel and Pycnometer Design

Balance, Containers and To utilize data for mix

Moisture Content __ before & during the work
frying pan Design
To assess the quality of
Balance, 90 Micron sieve Residue less than 10
Fineness Test cement used in before & during the work
and Brush Blains Apparatus percent
construction
Vicat Apparatus with 10mm
Normal Consistency before & during the work
dia Plunger.
Initial-Not less than 30
3 CEMENT Initial and Final Vicat Apparatus with Initial
minutes. Final – Not before & during the work
setting time and Final setting needles
more than 600 minutes
Le-Chatelier expansion
Soundness Test Le-Chatliers Apparatus before & during the work
less than 200 mm
Specific Gravity bottle,
Specific Gravity
Kerosene
OPC 3days 7days
Cube Moulds 7.06 Cm, 28days43grade 23N/
Compressive Vibrating Machine and mm2 33N/mm2
During the work
strength Compression Testing 43N/mm253grade
Machine 27N/mm2 37N/ mm2
53N/mm2

66
 Prism Mould (50X50X200),
Drying shrinkage
rod of 205 mm.

chemical Analysis
To Check workability of
Temperature & Slump Cone with Rod,
Concrete/ Water-Cement __ During the work
Slump Industrial Thermometer
ratio
Batch Mixer, Vibrating
Compressive
Table, Cube Moulds, To assess 28 days
Strength of Concrete __ During the work
Compression Testing compressive strength
Cubes
Machine, Balance
Concrete Core Drilling To assess the density,
C C Core Extraction Machine with various segregation and __ After the work
diameter drill bits compressive strength
Residue less than 10
percent
To know the Permeability
4 CONCRETE Permeability, Water Not less than 225
Permeability of Concrete used for before & during the work
reservoir, Pressure lines m2/Kg for OPC, and Not
Lining
less than 300 m2/Kg for
PPC.
Rebound hammer
Rebound hammer
Apparatus
Ultrasonic pulse
Pulse Velocity Apparatus
velocity
Compaction factor
test
Air content Air meter

Diameter and Weight To determine the diamter

__ before & during the work
Determination and weight
5 STEEL Tensile Strength (
UTM ),Elongation (
Universal Testing Machine __ before & during the work
UTM ), 0.20% Proof
Stress

67
 Bend and Rebend
__ before & during the work
Test

To Know thenature of
PH Value test As per IS 3025-1983 before & during the work
water

6 WATER Limits of acidity test

Limits of Alkalinity
test
Percentage of solids
such as Chlorides,
Sulphates
,Suspended Matter ,
Oraganic and
Inorganic impurities

TUNNELING
a)Access and haul
roads where cross
traffic or other
hazardous
conditions exist.
b)Bridges
c)Concrete placing
For improving
d)Underground Luxo meter(lux)
1 LIGHTING performance and quality __ During the work
works (Working Least Count=0.01 lux
in the working area
faces)
e)Junction
f)Operator’s cabin of
machines
g)Maintenance
shops and auxiliary
buildings
68
 I) Purity requirement
a)Carbon Monoxide Not More than 0.005%
b)Oxygen Not less than 19.5%

c)Hydrogen Sulphide Not More than 0.001%

Not More than 0.5% at
For improving any place inside the
Multi Gas Detector (PPM)
performance and quality tunnel , for Eg. In a During the work
Least Count=0.1 PPM
d)Methane in the working area cavity in the roof etc.
e)Carbon di oxide Not More than 0.5%
f)Nitrogen fumes Not More than 0.0005%
As formadehyde not
g)Aldehyde more than 0.0002%
2 VENTILATION
On tunnel work 4.25 m3
of Air / min / man is
usually consdiered the
minimum requirement.
In addition to this 2.0
II) Volume of Air
IS : 4576 - 1968 m3 of Air / min shall be
required
supplied for such brake
horse power of Diesel
locomotive or other
diesel engine used in
tunnel.
Ensure Temperatures of
not more then 40 º C
III) Temperature IS : 4576 - 1968
Dry and 29 º C wet at
working place
Sound Pressuire Level It is the level below which
a)Work limit value Meter very little risk to an __
Least Count=0.1 Db unprotected ear
NOISE
3
CONTROL Above which the danger
of hearing impairment and
b)Danger Limit Value During the work
deafness may result from
an unprotected ear.

69
 Worker should wear
c)Danger Limit Value appropriate ear During the work
protection.

Personal protective
d)Danger Limit Value During the work
equipment shall be worn.

No worker shall be
e)Danger Limit Value During the work
allowed to enter the area.
This limit value will be
applicable when the
respirable dust contains
5% or less silica in air
borne dust.Where dust The total dust if exceeds
Respirable dust in NCB/MRE Dust Sampler
DUST contains more than 5% 10mg / m3, ventilation
4 the work front during Type 113 A During the work
CONTROL quartz or free silica the shall be adequately
each shift IS : 4576 - 1968
limiting value shall be improved
determined by the
following formula (5 ÷ %
of respirable quartz or
free silicamg/m3)
To assess the bond
Pull Out Test on During the work
PULL OUT strngth of the embedded
5 Anchor bars and Central Hole Jack __ Specification as per IS
TEST rock bolts and anchor
Rock bolts code IS:11309-1985
bars
GROUND
Ground Penetration To assess the thickness,
6 PENETRATION GRP survey eqipment __ After the work
Radar homogenity
RADAR

SHOT CRETING
To Check workability of
Temperature & Slump Cone with Rod,
Concrete/ Water-Cement __ During the work
During Slump Industrial Thermometer
1 ratio
Construction
To Check the air content in
Air content Air meters __ During the work
fresh concrete

70
 Size shall not be less than To assess 7 days, 28 days
Unreinforced Test 75 cm * 75 cmand thickness Compressive strength,
__ During the work
Panels shall not be less than 7.5 Density and Segregation
cm of mix
To assess 28 days
C C Core Minimum Dia of 7.5 cm and Compressive strength,
__ After the work
Extraction L/D ratio greater than 1 Density and Segregation
of mix
To assess the bonding
between old Strucural After the work(ASTM
After hardening Bond strength Bond Strength tester __
Surface and shocrete C1583/C1583M)
2 and appropriately
Overlay
cured and aged.
Flexural
properties- for To assess the flexural
RDP test System __ After the work
Fiber Reinforced Strength
Shotcreting.
Ground To assess the thickness,
GRP survey eqipment __ After the work
Penetration Radar homogenity

BARRAGES/SPILLWAYS

a. Group Strain meter-6

Nos group/Block
b. No Stress strain meter-
6 Nos /Block
c. Stress meters -6
Nos/Block
d. Joint meters - 8 Nos
/Block
1 Instrumentation Measuring Device
e. Up lift pressure meters
- 8 Nos/Block
These are indicative and
f. Invert Plumb line -- 1
additional equipment shall
No/Block
be decided with the
g. Normal Plumb line- 1
approval of Chief
No/Block
Engineeer/CDO
h. Automatic water level
Indicators- 1 Set /Block
71
 i. Multi point bore
Extensometer- 1 No/Block
j. Inclinometer - 1 Set
/Block
k. Switch cum junction
boxes - 6 Nos/Block
l. Readout unit - 1
No/Block
m. Cable point housing - 6
Nos/Block

n. 10core Insulated copper

cable - 2000m per block
o. 20 core Insulated copper
cable - 200m per block

p. 40 core Insulated copper

cable - 1000m per block
1 Instrumentation Measuring Device q. Temperature meter -8
Nos/Block
r. Pore pressure meter - 8
Nos/Block
s. Strong Motion
Accelerometer -1 Set /Block
t. Automatic Data
Acquisition Station - 1
No/Block

Viscometer with Cup and

Bentonite (cut of Cut off Trench To find the movement of
2 Bob (or) Viscometer with During the work
trench) rhelogy test Bentonite slurry
Plate and Cone

72
EARTH DAM AND CANAL EMBANKMENTS

Electronic weighng balance

500 g Capacity, Counter As per design
scale balance 20 kg To know the classifications
Grain size analysis
capacity, sieves 4.75 mm, of soil actually put in the Before & During the work
for classification
2.36 mm, 1.18mm, embankment
600microns, 300 microns,
150 microns, 75 microns.
Workable range for
hearting
To know the classifications
Liqid Limit device, Porecelin LL PL PI
Atterberg Limit test of soil actually put in the Before & During the work
dish, Groving tool, spatula 35 20 15
embankment
To To To
50 30 30
1 SOILS
Before & During the work
Hydrometer
Hydrometer test apparatus __ to know the percentage of
analysis
silt and clay
Before & During the work
Density Buttole of 50 ml To know the
Specific Gravity capacity Water bath, __ classifications of soil
desicators, glass road actually put in the
embankment
Minimum 98% of MDD.
During the work
Main canal and Branch
Field Density and To determine the Field
canal and 95% of
Moisture content density and moisture
Distributary & Dowel
content.
banks.
To determine permeability Workable range for
characteristics of the fill hearting, less than10-6
Permeability Test Permeability Apparatus During the work
material cm/sec. Casing more
than 10-4 cm/sec.
To know the shear
Shear box with all
Direct Shear Test characteristics of fill As per design Before & During the work
accessories
material (in-situ)
To know the shear
Shear box with all
Triaxial Shear Test characteristics of fill As per design Before & During the work
accessories
material (in-situ)
73
 consolidation ring and cell, To know the settlement
Dial gauge and laoding rate and its magnitude
Consolidation Test device,Trimming equipment As per design During the work
,balance

To determine MDD and

OMC of the soil and
Standard Proctor Core cutter, rammer ,dolly
compare the results with As per design Before & During the work
Test and all other accessories
Laboratory value

To know the moisture

Moisture content content of the sample As per design Before & During the work

Evoprating dish, shrinkage To determine shrinkage

dish, mesuring jar, mercury limited
Shrinkage Factor __ Before & During the work
250g

ID =( emax – e)/(emax –
Relative Density Relative Density Apparatus emin), e=Grw -1 /ra As per design Before & During the work

Swell Pressure test To know the swell

of Black cotton pressure of BC soils __ During the work
soils . Swell Pressure apparatus
To know the swell index of
Swell Index swelling soils __ Before the work

Subjected to σ1and
Unconfined σ2=σ3=0.The U.C Test is
Proving ring attached to a
Compressive applicable to saturated __ Before & During the work
load frame
strength case for which Ø is 0.
Insitu Tests on
Embankment
Field
Density/Compactio
n efficiency using
nuclear moisture __ During the work
To know compaction
density gauge ( Nuclear DensityGauge
efficiency
electronic
equipment )
74
 compaction
efficiency by core
cutter method

In-situ permeability 1. To know the water

test Japanese Permeability Apparatus,soil tightness of banking, 2. __ During the work
method extractor, oven Hearting < 10 - 6 cm /sec,
3.Casing >10-4 cm/sec
FILTERS

Grain Size To find % of the D10, D15,

Analysis for metal D30, D50, D60 and D85 __ Before & During the work
and sand grain sizes of materials

Clay lumps and To find out clay lumps &

Organic impurities level __ Before & During the work
organic impurities
a. Group Strain meter-6
Nos group/Block
b. No Stress strain meter-
6 Nos /Block
c. Stress meters -6
Nos/Block
These are indicative and
d. Joint meters - 8 Nos
additional equipment shall
/Block
1 Instrumentation Measuring Device be decided with the
e. Up lift pressure meters approval of Chief
- 8 Nos/Block Engineeer/CDO
f. Invert Plumb line -- 1
No/Block
g. Normal Plumb line- 1
No/Block
h. Automatic water level
Indicators- 1 Set /Block

75
 i. Multi point bore
Extensometer- 1 No/Block
j. Inclinometer - 1 Set
/Block
k. Switch cum junction
boxes - 6 Nos/Block
l. Readout unit - 1
No/Block

m. Cable point housing - 6

Nos/Block
n. 10core Insulated copper
cable - 2000m per block
o. 20 core Insulated copper
cable - 200m per block
p. 40 core Insulated copper
cable - 1000m per block
q. Temperature meter -8
Nos/Block
r. Pore pressure meter - 8
Nos/Block
s. Strong Motion
Accelerometer -1 Set /Block
t. Automatic Data
Acquisition Station - 1
No/Block

ROAD WORKS

IS: 1203-1978

IS: 1208-1978
1 BITUMEN
IS: 1205-1978

IS: 1202-1978

76
 To assess its IS: 1206-1978
consistency, gradation,
viscosity, temperature IS: 1209-1978
susceptibility, and
safety. IS: 1210-1978
IS: 1211-1978

IS:1212-1978

Note:

1. The list of equipment shown above is indicative. Additional equipment if any, required for successful completion of work Shall be provided or arranged
by the contractor.

2. The cost of laboratory building including services, essential supplies like water, electricity, sanitary and their maintenance and cost of all equipment,
tools, materials, labour and incidentals to perform tests and other operations of quality control according to the specifications requirement shall be
deemed to be incidental to the work and no extra payment shall be made for the same.
3. The Engineer-In-Charge / Agreement concluding authority shall verify the lab equipment procured by the agency. If the agency has not procured lab
equipment then the Engineer-In-Charge / Agreement concluding authority shall procure the equipment and recover the cost of equipment from the
agency payments .

77
BLANK PAGE

78
 QUALITY CONTROL CHECKS TO BE PERFORMED ON MAJOR COMPONENTS OF EM ( Electro-Mechanical ) & HM ( Hydro-Mechanical)
EQUIPMENT
(T = Type Test : R = Routine test : N.A = Not applicable)
Dimension Insulatio Material
Rating Fault High Temper
al checks Fault n Functio Mod compositi
(Capacity curre voltag ature Effciency
Sl. No Item/ Equipment like length, Make Type current resistanc nal el on
, Voltgae nt e rise tests
weight, rating e ( IR checks test checks/
Current) level tests tests
size etc value) tests
A Tests & Checks to be Done at works (Ex-Factory)
1 Startor & Rotor of Motor R R R R R R R N.A T T T T T
2 Pumps R R R R N.A N.A R T N.A N.A N.A N.A T
Guide vanes, shafts, impeller,
3 Valves, draft tube gates, R R R R N.A N.A R N.A N.A N.A N.A N.A T
Pressure mains
Oil & Air receivers of guide
4 vanes/ Discharge valve R R R R N.A N.A R N.A N.A N.A N.A N.A T
operating system
5 Air compressors , Air Receivers R R R R R R R N.A N.A N.A N.A N.A T
6 Transformers R R R R R R R N.A T T T T T
7 Control panels R R R R R R R N.A T T T T T
8 H.T Panels R R R R R R R N.A T T T T T
9 L.T panels R R R R R R R N.A T T T T T
10 Cables R R R R R R R N.A T T T T T
11 E.O.T cranes & Gantry cranes R R R R R R R N.A T T T T T
12 Lifts R R R R R R R N.A T T T T T
13 Lighting equipment R R R R R R R N.A T T T T T
14 Air conditioning equipment R R R R R R R N.A T T T T T
15 Ventilation system R R R R R R R N.A T T T T T
16 Capacitor banks R R R R R R R N.A T T T T T
17 Switch yard equipment like
breakers, C.Ts. P.Ts. L.As. R R R R R R R N.A T T T N.A T
Isolators and earth switches

(NOTE : Testing procedures for Items shall be as per the Indian standard specifications and the manuals of respective Manufacturing Companies)

79
 QUALITY CONTROL CHECKS TO BE PERFORMED ON MAJOR COMPONENTS OF EM ( Electro-Mechanical ) & HM ( Hydro-Mechanical )
EQUIPMENT
( T = Type Test : R = Routine test : N.A = Not Applicable)
Dimensi Rating Insulation
Functinal Fault current High voltage Effciency
Sl. No Item/ Equipment onal Make Type (Capacity, Resistance
checks rating Tests tests
checks Voltgae Current) (IR value)
B Tests & Checks to be done at site (During/after errection)
1 Startor & Rotor of Motor R R R R R R N.A N.A
Field
2 Pumps R R R R N.A N.A N.A N.A efficiency
Guide vanes, shafts, impeller, Valves, test
3 R R R R N.A N.A N.A N.A
draft tube gates, Pressure mains
Oil & Air receivers of guide vanes/
4 R R R R N.A N.A N.A N.A N.A
Discharge valve operating system
5 Air compressors , Air Receivers R R R R N.A N.A N.A N.A N.A
6 Transformers R R R R R R N.A R N.A
7 Control panels R R R R R R N.A R N.A
8 H.T Panels R R R R R R N.A R N.A
9 L.T panels R R R R R R N.A R N.A
10 Cables R R R R R R N.A N.A N.A
11 E.O.T cranes & Gantry cranes R R R R R R N.A N.A N.A
12 Lifts R R R R R R N.A N.A N.A
13 Lighting equipment R R R R R R N.A N.A N.A
14 Air conditioning equipment R R R R R R N.A N.A N.A
15 Ventilation system R R R R R R N.A R N.A
16 Capacitor banks R R R R R R N.A R N.A
17 Switch yard equipment like breakers,
C.Ts. P.Ts. L.As. Isolators and earth R R R R R R N.A R N.A
switches
18 Switch yard structural material,
structures material, earthing system,
R R R R R N.A N.A R N.A
Earth resistance measurements,
conductor size and clearances
(NOTE : Testing procedures for Items shall be as per the Indian standard specifications and the manuals of respective Manufacturing Companies.)

80
 CHAPTER – XI

LIST OF EQUIPMENT FOR WORKS COSTING LESS THAN 2 CRORES

11.0. SOILS:

1. (i) Electronic weigh Balance 6kg, (ii) Electronic weigh Balance 600gmx0.01g.
(ii) Sieves 4.75mm, 2.36mm, 1.18mm, 600micron, 300micron, 150micron and 75 micron,
Pan and cover
2. Sieve Shaker, Motorized, with Built-in Digital Timer
3. Liquid Limit Device,
4. Plastic Limit set
5. Shrinkage Limit Set.
6. Specific Gravity Test
7. Hydrometer, Analysis with all accessories
8. Filter paper.
9. Compaction Test Apparatus for heavy compaction.
10. (i) Cylindrical Core Cutter, made of steel 100mm dia x 130mm long alnog with dolly
including Rammer, with Steel Rod, Straight Edge, Trowel, Tray etc.,
(ii) Sand Pouring Cylinder Apparatus, 100mm Dia The equipment consist of the following
parts : sand pouring Cylinder, Cylinder Calibration Container 100mm ID x 150mm
height, Metal tray size 30x30x4 cm, with 10cm central hole.
11. Relative Density Apparatus.
12. Sand Pouring Cylinder Apparatus
11.1 COARSE AGGREGATE:
1. (i) Sieves for Coarse Aggregate
2. Sieves G.I. Frame 30cm dia x 80mm, 40mm,20mm, 12.5mm, 10mm, 4.75mm, 2.36mm,
pan and cover
(ii) Electronic weigh balance 20kgs
(iii) Thickness Gauge with ISI Certification Mark IS:2386 (Part I)
(iv) Length Gauge with ISI Certification Mark IS:2386 (Part I)
3. (i) Sieve G.I. Frame 45cm dia x 31.5mm, 16mm, 8.6mm.
11.2 CEMENT:
1. (i) Vicat Apparatus with ISI Certification Mark, IS:5513, fitted in Aluminium Box.
(ii) Consistency Plunger (in Plastic Case).
2. Le-Chatelier Mould, with ISI Certification MarkIS:5514, each.
3. Cube moulds for cement testing

81
11.3 CONCRETE:
1. Slump Test Apparatus with testing rod and base plate.
2.PH Balance
3. (i) Mould, Cast Iron, of 150mm x150mm x 150mm Cube with ISI Certification Mark.
(ii) Tamping Rod, Steel, 16mm dia x 600mm length with ISI Certification Mark, IS:10086.
(iii) Digital Compression Testing Machine, Capacity 1000kN.
11.4 MORTAR:
1. Moulding tray for cubes Beaker (for taking water) including Tamping Rod, Steel, 16mm
dia and Stop Watch 'Mechanical' 1/5 se.
2. Mould, Cast Iron, of 75mm x75mm x 75mm Cube with ISI Certification Mark.

11.5 GENERAL:
1. Auto level 24X with stand and 6m staff.
2. Spring Balance 50 Kg.
3. Measuring Tapes.
4. Rodometer PVC Wheel.
5. Oven
6. Thermometer.
Note:
1. The list of equipment shown above is indicative. Additional equipment if any, required for
successful completion of work Shall be provided or arranged by the contractor.
2. The cost of laboratory building including services, essential supplies like water, electricity,
sanitary and their maintenance and cost of all equipment, tools, materials, labour and incidentals
to perform tests and other operations of quality control according to the specifications
requirement shall be deemed to be incidental to the work and no extra payment shall be made for
the same.
3. The Engineer-In-Charge / Agreement concluding authority shall verify the lab equipment
procured by the agency. If the agency has not procured lab equipment then the Engineer-In-
Charge / Agreement concluding authority shall procure the equipment and recover the cost of
equipment from the agency payments .

82
 CHAPTER – XII
LIST OF EQUIPMENT FOR WORKS COSTING MORE THAN 2 CRORES

12.0 SOILS:

1. (i) Electronic weigh Balance 6kg, (ii) Electronic weigh Balance 600gmx0.01g.
(ii) Sieves 4.75mm, 2.36mm, 1.18mm, 600micron, 300micron, 150micron and 75 micron,
Pan and cover
2. Sieve Shaker, Motorised, with Built-in Digital Timer
3. Liquid Limit Device,
4. Plastic Limit set
5. Shrinkage Limit Set.
6. Specific Gravity Test
7. Hydrometer, Analysis with all accessories
8. Direct Shear Test Apparatus 2 kN capacity
9. Triaxial Shear test Apparatus
10. Swell Test Apparatus.
11. Free Swell Test Apparatus
12. Consolidation Apparatus.
13. Compaction Test Apparatus for light compaction
14. Compaction Test Apparatus for heavy compaction.
15. (i) Cylindrical Core Cutter, made of steel 100mm dia x 130mm long alnog with dolly
including Rammer, with Steel Rod, Straight Edge, Trowel, Tray etc.,
(ii) Sand Pouring Cylinder Apparatus, 100mm Dia The equipment consist of the following
parts : sand pouring Cylinder,Cylinder Calibration Container 100mm ID x 150mm height,
Metal tray size 30x30x4 cm,with 10cm central hole.
16. Rapid Moisture Meter.
17. Relative Density Apparatus.
18. In-situ Permeability test Apparatus including soil extraction etc., complete.
19. Laboratory Permeability Apparatus.
20. Standard Penetration Test (SPT) Set.
21. Laboratory California Bearing Ratio Test Apparatus.
12.1 COARSE AGGREGATE:
1.(i) Sieves for Coarse Aggregate for road
2.Sieves G.I. Frame 30cm dia x 80mm, 40mm,20mm, 12.5mm, 10mm, 4.75mm, 2.36mm, pan
and cover
(ii) Electronic weigh balance 20kgs
(iii) Thickness Gauge with ISI Certification Mark IS:2386 (Part I)
(iv) Length Gauge with ISI Certification Mark IS:2386 (Part I)

83
 3. Alkali aggregate reactivity test scales
4. (i) Sieve G.I. Frame 45cm dia x 31.5mm, 16mm, 8.6mm.
(ii) Solution of sodium or magnesium sulphate.
5. (i) Sodium hydroxide.
(ii) graduated glass bottle.
6. Petrography by animation hammer.
7.(i) Aggregate Impact Tester.
(ii) Crushing Value Apparatus.
8. Los Angeles Abrasion testing machine with Counter.
9.Digital length comparator with air tight lid and rod.
12.2 CEMENT:
1. (i) Vicat Apparatus with ISI Certification Mark, IS:5513, fitted in Aluminium Box.
(ii) Consistency Plunger (in Plastic Case).
2. Le-Chatelier Mould, with ISI Certification MarkIS:5514, each.
3. Cube moulds of size 75mm x75mm x75mm for cement testing
4. Lab cement autoclave
5. Shrinkage bar mould
6. Vibrating machine
7. Length comparator
8.Prism mould (50x50x200), rod of 205mm
12.3 CONCRETE:
1. Slump Test Apparatus with testing rod and base plate.
2. PH Balance
3. (i) Mould, Cast Iron, of 150mmx 150mm x150mm Cube with ISI Certification Mark.
(ii) Tamping Rod, Steel, 16mm dia x 600mm length with ISI Certification Mark, IS:10086.
(iii) Digital Compression Testing Machine, Capacity 2000kN.
(iv) Universal Testing Machine.
4. U.S.P.V Machine.(Ultra Sonic Pulse Velocity)
5. Digital Rebound hammer.
6. Concrete Penetrometer, Spring Type.
7. Core Drilling Machine Including with core bit 75mm, 100mm,150mm dia (Hilty) including
generator.
8.Concrete Mixer, Drum Type, Capacity 1 Cubic Feet.
9.Vibrating Table, 50 x 50cm for 4 moulds of 150mm cube.
12.4 MORTAR:
1. Moulding tray for cubes Beaker (for taking water) including Tamping Rod, Steel, 16mm
dia and Stop Watch 'Mechanical' 1/5 se.
2. Mould, Cast Iron, of 75mm x75mm x 75mm Cube with ISI Certification Mark.

84
12.5 TUNNELLING
1. Luxometer(lux)
2. Multi gas Detector(PPM)
3. Centre Hole Jack
4.Sound Pressure Level Meter
12.6 SHOT CRETING
1. RDP – (Round Determinant Panel) Test system.
2. GRP – (Ground Penetrating Radar Equipment).
3. Bond Strength tester
4. Air Meters
12.7 GENERAL:
1. Total station.
2. Auto level 24 X with stand and 6m staff.
3. Spring Balance 50 Kg.
4. Measuring Tapes.
5. Rodometer PVC Wheel.
6. Oven
7. Thermometer.
8. Burrete
9. Measuring cylinders and flasks,
10.Radiography Facilities,
11. Mechanical weighing balance
12. Ultrasonic testing machinery
13. DP test kit
14. Vernier Callipers
15.Micrometer
16.Radiography film viewer
17. Inside meter

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

85
 CHAPTER – XIII

FORMATS OF TEST RESULTS

………………………………….. IRRIGATION PROJECT

Determination of Field Moisture and Dry Density of Compacted Earth fill

1. Date :

2. Sample No. :

3. Wt. of Core Cutter: Soil in gms (Ws) :

4. Wt. of Wet Soil in gms (Ws-Wc) = M :

5. Wet Density gms/c.c. = W / V :

6. Moisture container No. :

7. Wt. of container + Wet soil in gms. :

8. Wt. of container + dry soil in gms. :

9. Wt. of moisture in gms. (m) :

10. Wt. of dry soil in gms (d) :

% moisture content (m.c) = m x 100 / d

11. :

12. Dry density in gms/cc.

Signature of A.E./A.E.E Signature of D.E.E.

86
 …………………………….. IRRIGTION PROJECT

Register for Compaction Efficiency Determination

Date Sample No. Location of Field Earth Fill Zone

Sample R.D. Classification
Off-R.L. Set
1. 2. 3. 4. 5.

Embankment Data Laboratory Data Compaction

W.D. Dry M.C. % % OMC MDD Gms/C.C. %
Density
6. 7. 8. 9. 10. 11. 12.

Signature of A.E./A.E.E Signature of D.E.E.

87
 ................................ IRRIGATON PROJECT

Testing Results of Post Checking of rolled fill of Dam/Canal Embankment

(Central Lab Test)

S.No. Date of Lab Sample Location Rolled Fill

Sampling No. CH. Off-L/R Dry Density
Gms./CC
1. 2 .3. 4. 5. 6.

M.C. of the Fill Permeability of U/D Performed as per REMARKS

Sample Mt. / Yr. Frequency (Dam
every alternate day
and Canal Weekly)
7. 8. 9. 10.

Signature of A.E./A.E.E Signature of D.E.E.

88
 ………………………………. IRRIGATION PROJECT

Testing Results of Soil Samples of Borrow Area (Central Laboratory)

S. No. Date of Lab. Location Natural Natural

Sampling Sample Borow Offset R.L. M.C. % Dry
No. Density
gms/C.C.
1. 2. 3. 4. 5. 6. 7. 8.

Specific Grain size Analysis (I.S.No. 480) Proctor’s Compaction

Gravity Gravel Sand 4.75 Silt 0.75 to Clay 0.002 % OMC M.D.D.
4.75 to 0.075 0.002 mm mm Gms/cc
mm% %
9. 10 11. 12. 13. 14. 15.

Permeability At OMC Atterberges Limits Shear Test at O.M.C. & REMARKS

mt/yr. U/D MDD M.D.D.
L.L. P.L. P.I. Drained / Undrained/
Saturated/ Gms/C.C.
16. 17. 18. 19. 20. 21. 22.

A.E./A.E.E. D.E.E.
CENTRAL LABORATORY CENTRAL LABORATORY

89
 …………………………………….. IRRIGATION PROJECT

Test Results of Sand Samples conducted at Central Lab/Field

LAB ……………………………

Location Quarry/Stock Ref: _______________________

PERCENTAGE OF PASSING FOR

I.S. Grading Grading Grading Grading

Sample
Description Zone-I Zone-II Zone-III Zone-IV

1. 2. 3. 4. 5. 6.
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 micron 15-34 35-59 60-79 80-100
300 micron 5-20 8-30 12-40 15-50
150 micron 0-10 0-10 0-10 0-15

F.M. __________ SILT __________ BULKAGE __________

REMARKS __________

Signature of Signature of
A.E./A.E.E. D.E.E

90
 ………………………. IRRIGTION PROJECT

Testing Results of Coarse Samples of Borrow Area (Central Laboratory)

Field Lab: __________

Location Quarry Stock Ref: __________

I.S. SIEVE
Percentage Passing for Graded Aggregate or Normal Size
Description

Sample 40 mm 20 mm 12.5 mm

80 mm 100

40 mm 95-100 100

20 mm 30-70 95-100 100

12.5 mm -- -- 90-100

10 mm 10 to 35 25-55 40-85

4.75 mm 0 to 5 0-10 0-10

2.36 mm -- -- --

Crushing Value (>45) __________ Impact Value (>45) __________

Abrasion (>50) __________ Absorption __________

Soundness Loss > 12% for Na2 SO4

> 15% for Mg SO4

Signature of Signature of
A.E./A.E.E. D.E.E

91
 ……………………. IRRIGATION PROJECT

Test Results of Cement Samples (Central Laboratory)

Name of the Godown __________ for use in structure __________

Manufactured at __________ factory __________ Ref: __________

S. Sample Lab. Size Physical, Specific Compressive LE Remarks

No. No. No. of Tests Surface Strength Test Chat
Cube Setting Cube Kg/Cm2 Test
Times

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

A.E./A.E.E. D.E.E.
CENTRAL LABORATORY CENTRAL LABORATORY

92
 ………………………. IRRIGATION PROJECT

Test Results of Stone Samples Conducted at Central Laboratory __________

Location Quarry Stock _______________ Ref: _______________

S. No. Lab Sample Wt. of Size Absorption Density

Individual LXBXH (%) Gm/CC
Piece Kg.
1. 2. 3. 4. 5. 6.

Soundness Abrasion Abrasion Visual Curing General

With Acid Remarks
Na2So4 Reaction including
with HCL Suitability
conc.
7. 8. 9. 10. 11. 12.

A.E./A.E.E. D.E.E.
CENTRAL LABORATORY CENTRAL LABORATORY

93
 ……………………. IRRIGATION PROJECT

Test Results of Water Samples conducted at Central Laboratory __________

Location River

Reservoir _______________ Ref: _______________

Storage

For use in concreting/mortar/curing/other _______________ purpose in

Structure at __________________________

Qualitative Tests Percentage of Quantitative Tests

S. Silt & Total
Sample Remarks
No. SO4 CO3 CI NO PO Ph Suspended Soluble
Impurity Salt
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

A.E./A.E.E. D.E.E.
CENTRAL LABORATORY CENTRAL LABORATORY

94
 ………………………..IRRIGATION PROJECT

Test Results of HYSD Bars Samples Conducted at Central Lab

Location Godown __________ for use Structure __________

Work site

Manufactured at ____________________ Factory _______________

Ref: __________________

MECHANICAL PROPETIES OF HIGH YIELD STRENGTH DEFORMED BARS

S.
Properties Sample Grade
No.
Fe 415 Fe 500 Fe 550
0.2 percent proof stress/yield
1. 415 500 550
stress Min. N/mm2
Elongation percent Min. on
guage length (5.65√A, where
2. 14.5 12 8
A is cross sectional area of
test piece.
10% more than 8% more than 6% more than
the actual 10.2% the actual 0.2% the actual 0.2
3. Tensile Strength Min. proof stress but proof stress but proof stress but
not less than the not less 545 not less than
485 N/mm2 N/mm2 585N/mm2

Signature of Signature of
A.E./A.E.E. D.E.E

95
 ………………………… IRRIGATION PROJECT

Test Results of Hardened Samples Conducted at Central Laboratory ______________

Concrete Designed Concrete Mix

Location of Sample Test Results
Cube No. Properties
Comp. 7 days 28 days
CH. Off W/C Strength. Comp. Comp.
Block
R. Set Proportion 28 days Strength. Strength.
Kg/Cm2 Kg/Cm2 Kg/Cm2

Designed Mortar Mix Properties Test Results

Comp. Comp. Stren.
Comp. stren. 7 Remarks
W/C Prop. Strength of 28 28 days
days Kg/Cm2
days Kg/cm2 Kg/Cm2

A.E./A.E.E. D.E.E.
CENTRAL LABORATORY CENTRAL LABORATORY

96
 …………………………… IRRIGATION PROJECT

Test Results of Common Brick Samples Conducted at Laboratory Location

for use in ____________________ at ____________________

Samples mark of Ref. _______________ Lab No. _______________

S. Properties of Bricks I.S. 3102-1965

Observation Remarks
No. & I.S. 3367-75

1. 2. 3. 4.

1. Colour

2. Burnt Character

3. Shape

4. Edges

5. Texture after breaking

6. Sound when struck

7. Efflorescence

8. Tolerance % on dimension

9. Compressive strength Kg/Cm2

10. Water Absorption

Checked & Supervised Signature of

A.E.E./A.E. Deputy E.E.
Laboratory Laboratory

97
 ……………………………. IRRIGATION PROJECT

Test Results of Concrete / Mortar Cubes Casted by Quality Control Staff @ Site

R.D. __________ To __________ of structure __________

Date of Mark on the

Sample No. Location of Sample
Casting Cube
Block R.D. Offset R.L.
1. 2. 3. 4. 5. 6.

Compressive Strength Designated

of Concrete/Mortar 28 days
W/C Cube in Kg/Sq. Cm. Strengths
Proportion Slump Remarks
Ratio of Cube
7 days 28 days Mortar
Kg/Sq.cm
7. 8. 9. 10. 11. 12. 13.

A.E./A.E.E. D.E.E.
CENTRAL LABORATORY CENTRAL LABORATORY

98
 CHAPTER – XIV

IMPORTANT EXECUTION PROCEDURES AND SPECIFICATIONS

14.0 EARTH WORK

(IS CODES, 2720, 4701, 8237, 9451, 9481, 1200)

14.0.1 EXCAVATION OF CANALS

PROCEDURE FOR EXECUTING EARTH WORK

(A) General:
i) Sufficient number of reference Bench marks for facilitating setting out works and
taking levels shall be established.
ii) Permanent reference lines and check profiles at suitable intervals for checking the
execution of all slopes, steps and elevation of the profiles of the approved drawings,
shall be established.
iii) The entire area required for setting out, shall be cleared of all tree stumps, roots, bush
wood, rubbish of all kinds, loose and all objectionable materials.
(B) Stripping:
i) The work area shall be stripped of the surface soil, including vegetation, overlying
grass, organic matter, bushes, roots and other perishable or unsuitable material before
commencing of the excavation. It shall be done as per the requirement or to a
maximum depth of 0.30 m or as specified or as directed by the Engineer-in-charge.
ii) Prior to starting the stripping, initial cross-sections shall be taken at suitable interval
of 10 m to 30 m, or as specified or as directed by Engineer-in-charge and shall be
recorded in ink directly in the field books.
iii) After the work of stripping in the canal width is completed, detailed cross sections
shall be taken as specified or as directed by Engineer-in-charge to form the base for
computing the quantities of excavation or embankments.
(C) Borrow Area:
i) In case when the materials required for construction of different zones of embankment
and backfill around the structures are not available from canal excavation foundation
excavation, the same are to be obtained from the approved borrow area, designated
within the reasonable lead or as directed by the Engineer in charge.
ii) Borrow pits, along the canal shall be operated in special case only after due approval
of the competent authority keeping in view the hydraulic gradient line. This should
not impair the usefulness of soil; the appearance of any part of work or any other
property.

99
 iii) The stripping of borrow areas shall be done as per "B (i)" above.
iv) Necessary grid lines with base line at suitable intervals shall be marked prior to and
after stripping to take the levels of the cross-sections to compute the quantity of
stripping and the materials borrowed from the borrow area.
v) Necessary sample from the different depth shall be collected and got tested for their
suitability in different zones of embankment / backfill prior to commencing the
borrow area.
vi) The required moisture as determined by the laboratory test shall be introduced in to
the borrow area itself, by watering well in advance of the excavation to ensure
uniformity of moisture content.
vii) Moisture control register shall be maintained looking to the day to day initial
moisture content of borrow area's material and the optimum moisture content of the
respective material obtained from proctor tests.
viii) The depth of cut in all borrow areas and borrow pits shall be designated by the
Engineer-in- charge. Each borrow area shall be fully exploited to avoid haphazard
exploitation. The borrow area excavation shall be carried out in such a way so as to
produce the required uniformity mixture of materials for the embankment with the
available excavation machinery.

DOS DO NOTS
1. Fixup the centre line and set the curves 1. Do not avoid approval of the deviation
correctly. statement.
2. Take working levels, real variation in 2. Avoid over break and loosening of canal.
ground levels and classification of soils
as per Govt. Memo No. 1970-12/72-11,
dated 4-7-1994.
3. Get top soil vegetation etc., removed. 3. Do not mixup useful soils with other soil
of cutting.
4. Provide treatment with C.N.S. soils in 4. Unsighty heaps should be avoided.
B.C. reaches (Expansive soils)
5. Form spoil bank as per drawing and away
from side drain with suitable gaps for
drainage into the valley.
6. Form Dowel Bank, as per drawing.
7. Form Inspection path to a uniform
longitudinal gradient and with gentle
transverse slope towards toe drains.
8. Compact over excavation/breakage
portion with suitable soils, gravel, spalls.

100
14.0.2 FORMATION OF EMBANKMENTS

(D) Embankment:
(IS:4701:1982) (IS:14690:1999) (IS:2720:part33)

i) This may be in the reaches of canals in partial cutting and partial banking or in full
banking with or without bed banking.
ii) Before commencement of the work, it shall be ensured that the materials for different
zones of approved section, based on laboratory tests are available.
iii) Stripped ground shall be scarified and loosened by using plough or ripper.
iv) The base-seat for embankment to receive earth shall be watered to the required
moisture content and shall be compacted with suitable type of compactor so as to
attain 98% compaction or as specified.
v) The layers for the embankment portion shall be placed continuously and
approximately in horizontal loose layers of thickness 22.5 cm (9”) in depth, in the
respective zone, to the full width of the embankments, including slopes at the
respective level, if it is mentioned in the agreement categorically otherwise the loose
layer thickness shall be as per the approved test sections and to get required
compaction efficiency. However, the loose layer thickness shall be less than 30 cm.
This thickness is irrespective of soil type and compactors etc., for canal or earth dam
embankment works.
vi) Construction of embankment shall begin at toe of the fill and in no case material shall
be dumped from the top, to widen the embankment.
vii) Adequate Proud Section not less than 20 cm in thickness measured perpendicular to
the slope or as specified shall be provided on canal lining side and outer side.
viii) Each layer shall be tested for FDD and FMC as per the frequency stipulated in the
tender specifications.
ix) No fresh layer shall be laid until the previous layer is properly watered & compacted
as per requirement.
x) For proper bond of the embankment done in the previous season with new
embankment, care shall be taken as under:
a. In case of the bank to be extended horizontally, it shall be cut to a longitudinal slope
not steeper than 1 in 5 and the benching is to be with 0.6 m width tread and necessary
watering shall be done.

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 b. If the old bank is to be raised vertically, vegetation shall be cleared followed by
scarifying, watering and placing of new earth layer as specified above.
c. The rain cuts, if any, shall be made good with due care by filling with proper /
selected soil duly watered and compacted with suitable compactors or tempers.

(E) Important Features

i) Laboratory testing of soil to be used shall be done well in advance.
ii) Borrow areas to be identified looking to the suitability of soil available for different
zones of the embankment.
iii) Water content control to be exercised rigorously either by borrow area watering or
spreading it uniformly over loose layer before rolling.
iv) Proper roller should be selected for compaction, with the help of field compaction
trial and the type of soil e.g. pad foot / sheep foot roller for cohesive soil, vibratory /
random roller for cohesion less soil and OMC of the soil is to be used for compaction
can be determined.
v) Thickness of loose layer shall be controlled for the embankment works are as
follows:
(a) For all types of compaction equipment the loose layer shall be of 22.5 cm (9”)
thick or as per agreement. However loose layer thickness shall be based on test
section and in any case shall not be more than 0.30m thick irrespective type of roller
and type of soil.
(b) For Coarse Grained soils, by vibratory roller compaction, the loose layer
thickness can be 0.375 m. However we don’t use these type of soils for embankment
construction of irrigation works.
vi) Regular tests for field permeability, shear tests, field density and moisture control etc.
shall be conducted as per provisions/codes.
vii) No fresh layer shall be laid until the previous layer is properly watered and compacted
as per requirement and tests are taken and recorded.
viii) In case of works with cohesion less soil, where compaction test for MDD/OMC is not
feasible, it shall be compacted to at least 70% of RD or as directed by the Engineer -in -
charge.
ix) When the filters are to be provided filter material to be used shall be checked for
gradation curves and filter criteria's provided in tender. Compaction shall be done as
specified.

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 DOS DO NOTS
1. Get the top spoil, vegetation and sand 1. Do not raise the bank in piecemeal
patches removed to complete depth.
2. Scarify the ground and wet properly. 2. Do not allow new layer without
scarification and wetting of old layer.
3. Obtain P.D OMC for the useful soils 3. Do not allow new layer unless
and borrow soils. required degree of compaction is
achieved.
4. Provide C.O.T.s according to height of 4. Don’t leave any loose layer unrolled
bank. at the end of the day in rainy season.
5. Raise embankment to full width with 5. Don’t allow compacted layer to be
uniform horizontal loose layer of 22.5 more than approved test section.
cm thickness or as per the approved
test section/agreement.
6. Break clods, remove roots, big 6. No new layer to be laid unless the
boulders other materials etc., larger over moisture layer is either
than 80mm from the soils used in completely removed or allowed to
embankment. dry.
7. Supplement deficit moisture whenever 7. Don’t dump soils in heaps.
required.
8. Provide 0.45 Mtr. extra offset on both 8. Don’t dump the soils in water and
sides of bank. slush.

9. Compaction with 8 to 10 tonnes power 9. No. of roller passes shall be as per the
roller/vibratory roller/sheep foot roller field trial tests to achieve required
as the case may be. degree of compaction.

10. Sheep foot roller compaction is 10. Do not forget to provide settlement
mandatory for expansive soils, required allowance of 2.5cm/mtr. Height of
in COT and hearting zones. bank for power roller compaction.
11. Conduct field compaction tests and 11. Don’t use expansive soils in banking.
determine compaction efficiency.
12. Check embankment profiles
periodically.
13. Ensure 8 minimum No. of passes or no.

103
 of passes as per the field trial tests.
14. Provide 10% allowance in setting
profile of the embankment or as per the
agreement condition.

Records to be maintained

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

14.1 CONCRETE
(IS CODES 383, 269, 2116, 2386, 456, 516, 1199, 3878, 9103)
14.1.1 PROCEDURE FOR EXECUTING R.C.C. WORK & CONCRETE FOR
STRUCTURES
(I) General:
i) Necessary TBM, Reference line etc. shall be maintained and kept undisturbed till
completion of the structure.
ii) The foundation or the concrete -surface of the structures shall have to cleared of the
objectionable matter before putting the concrete and shall be got approved from
competent authority.
iii) O.K. Card for placement of concrete shall be maintained.
iv) In case of earth foundation, all soft, loose mud and surface debris shall be scrapped
and removed. The surface shall be moistened to a depth of about 15 cm to prevent
absorption of water from the fresh concrete.
v) In case of old concrete surface, the surface shall be clean, rough and damp when
receiving the next lift by scrapping, chipping or by other suitable means.
(II) Materials:

104
A) Cement:
i) Ordinary Portland cement (OPC) conforming to relevant IS according to different
grades shall be used, in case foundation concrete or other mass concrete works, PPC
may be used if permitted.
ii) Samples from the stock of cement shall be collected in accordance with IS procedures
and shall be got tested well in advance as per the frequency specified.
iii) Cement older than 90 days shall not be used without retesting & prior approval of
Engineer-in-Charge.
iv) Daily Receipt and consumption record shall be maintained in Cement Account Book.
B) Fine Aggregates:
i) Sand to be used shall be brought from the approved river shoal or manufactured sand
from crusher approved by ISO/NAC/NCC only. It shall confirm to the requirement of
IS: 383-1970 and other relevant specifications.
ii) Sand should be tested for Fineness Modulus (F.M.) gradation, specific gravity.
C) Coarse Aggregates:
i) Coarse aggregate for concrete shall be clean, hard, dense and free from vegetation. It
shall be conforming to IS: 383-1970 or the Specifications concreted with the work.
Predominantly flaky and elongated aggregate shall not be used. Gravel / metal shall
be brought from only approved quarry and shall be tested for their gradation; specific
gravity, water absorption, impact and abrasion values, soundness, spectrographic
analysis, flakiness and elongation.
ii) Each grade of material ranging from 40 mm to 4.75 mm shall be stacked separately.
D) Water: Potable water free from any other deleterious or organic material shall be used.
E) Reinforcing Steel: TMT, H.Y.S.D. bars and M.S. bars or other structural steel
confirming to relevant IS codes shall be used as reinforcement. However, samples of such
bars shall be collected and got tested prior to their use as per the frequency specified in the
relevant specifications.

(III) Manufacturing of Cement Concrete:

i) The concrete mix shall be got designed in laboratory for various grades i.e. M10,
M15, M20 & other grade as specified, used proposed construction materials to
achieve the required workability & strength at optimum cement level for RCC works,
minimum grade of concrete shall be M20.
ii) The prescribed amount of different materials such as coarse aggregate, fine aggregate,
water, cement and AEA as per the mix design, incorporation correction for over/under

105
 size material and water absorption shall be measured at the Batching plant or weigh
batcher. Batching plant or weigh batcher shall operate within the limits of accuracy
specified. They shall be calibrated regularly to keep the combined inaccuracies in
feeding and measuring the material, water and cement within the specified limit.
iii) The concrete ingredients thus measured and fed shall be mixed thoroughly in batch
mixers for the prescribed time of mixing so as to uniform distribution of all the
constituent material resulting in dense, plastic, stiff concrete of uniform colour and
consistency.

(IV) Transporting, Placing & Compaction of concrete

i) Concrete shall be transported from the mixing plant to the placement position as
rapidly as possible, by use of transit mixer or suitable placers, conveyors etc.
ii) In case when chutes are used for concrete conveying, they shall be of such size and
shape as to ensure a steady uniform flow of concrete without segregation.
iii) Before placing of concrete, foundation surface or surface of old, concrete shall be
cleaned, roughened and damped.
iv) Concrete, as far as practicable, shall be placed directly in final position, and shall not
be caused to flow to avoid segregation.
v) In case of old concrete surface, it should be cleaned and chipping / cutting shall be
attempted as per requirement. Clearing with wire brush / roughening of surface shall
be done invariably.
vi) Hand placing of concrete shall not be permitted and it should always be insisted for
providing suitable means to convey the concrete to avoid free fall from unacceptable
height or angle.
vii) Cold joints shall be avoided. However, in unavoidable circumstances, if a cold joint is
formed then necessary remedial measures and contraction joint treatment shall be
done prior to resuming the placement of concrete.
viii) Concrete placed shall be concreted in final position within specified time. Re-tamping
of concrete shall not be permitted.
ix) Concrete shall be compacted with the help of suitable type of vibrators, (Normally it
shall be immersion type having vibrating head of 100 mm, operated at speed of at
least 6000 vibrations per minutes when immersed in the concrete). It shall be
compacted to achieve the desired density.
x) Necessary in-situ density test of green concrete shall be taken and records for it shall
be maintained.

106
 xi) The surfaces of the concrete vibrated and finished shall be even, smooth and free from
pockets, projections, honey-combing and other objectionable defects.

(V) Form Work:

i) Formwork to be used to confine the concrete for bringing shape and required lines
shall preferably be of steel and got approved from the Engineer-in-charge. Effective and
sufficient number of props and bracing shall be provided to prevent deformation due to
placing, vibrating and compacting concrete.
ii) The surface of formwork shall be such as to produce surface finishes as specified and
form work joints tight enough i.e. grout tight.
iii) Before fixing the formwork in line and level it shall be properly cleaned and oiled.
iv) Formwork fixed in position duly lines and leveled shall be inspected prior to
commencing of concrete and O.K. card shall be maintained.
a) Embedded parts shall be fixed in position with desired standard of
Geometry.
b) PVC water stops shall be fixed in position so as to have its bulb in the
centre of joint.
v) Formwork shall be removed as soon as the concrete has hardened sufficiently or
looking to the requirement of design. Due care shall be taken at the time of removal,
so as to avoid damage to concrete.
vi) Formed surfaces shall have finish F1, F2, F3, or F4 as specified in the relevant
specification. Similarly unformed surfaces, i.e., U1, U2, U3 and finish U4 shall be in
confirmity with relevant specifications. If concrete is to be repaired then the repair of
concrete shall be attended immediately as per the provisions contained in the relevant
specifications.

(VI) Curing of Concrete:

(A) Moist Curing:

i) Top surfaces of concrete shall be kept moistened by covering with hessian
cloth or wet jute bags or by sprinkling water or by any other effective
means as per agreement conditions.
ii) Steeply sloping or vertical surfaces shall be kept completely and
continuously moist by water.
iii) Concrete cured with water shall be kept wet at least for 14 days when
ordinary Portland Cement (OPC) is used as per agreement specifications.

107
 (B) Membrane Curing:
i) Membrane curing shall be done by application of suitable approved white
pigmented type curing compound.
ii) When curing compound is to be used, application shall commence
immediately after the finishing operations are completed. It shall be
applied with mechanical spray pump of insecticide or Jumbo mounted on
Work Bridge. Timely application of curing compound yields good results.
iii) Curing compound to be used shall be of approved quality and shall be got
tested for water retention and reluctance test, well in advance.
iv) Record for test results of consumption, reflectance and area covered by
curing compound shall be maintained, for this the O.K. card is evolved.

14.1.2 SPECIFICATIONS OF PLAIN AND REINFORCED CONCRETE

1. Proportioning & batching:

Design mix concrete (controlled concrete) shall be used for concrete of grade M10 and
higher. As per IS 456, the Nominal mix concrete may be used for concrete upto M20 or
lower mix. In proportioning concrete, the quantity of both cement and aggregate shall be
determined by mass. Water shall be either measured by volume in calibrated tanks or
weighed. Concrete shall be manufactured either in batching mixing plants/self loading
mixer or mechanical mixers of various capacities (14/10 or 10/7). Alternatively, mobile
self-loading weight batching-mixing and transporting mixers of suitable drum capacity can
be used, both for mixing and transporting concrete. The mix proportions shall be such as to
ensure the workability of the fresh concrete and when concrete is hardened, it shall have
the required strength, durability, and surface finish.

Proportions for Nominal Mix Concrete

Grade of Total quantity of dry Proportion of fine
Concrete aggregates by aggregate to coarse
mass per 50 kg of cement aggregate (by mass)
to be taken as
the sum of the individual
masses of fine
and coarse aggregate
(kg)
1 2 3
M5 800 Generally 1:2 but
M7.5 625 subject to an upper
M10 480 limit of 1:1.5 and a
lower limit of 1:2.5
108
M15 330
M20 250

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

2. Design Mix concrete:

(IS : 10262 (2009))
The mix shall be designed to produce the grade of concrete having the required
workability and characteristics strength not less than appropriate values given below:

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

M10 10
M15 15
M20 20
M25 25

The concrete mix shall be designed for the 'target mean strength'. The target mean
strength of concrete mix should be equal to characteristic strength plus 1.65 times the
standard deviation.

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

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

Grade of concrete Assumed standard deviation

M10 3.5
M15 3.5
M20 4.0
M25 4.0

Water cement ratio (W/C):

Water cement ratio is one of the key elements for a durable and sound concrete of
adequate strength. Accordingly, water cement ratio shall be maintained at correct value.

109
 The water contents in both fine and coarse aggregate shall be determined regularly. The
amount of water to be added shall be adjusted to compensate for any observed variation in
moisture content. The amount of surface water may be estimated from the following table
in the absence of exact data:
S. Approx. quantity of surface water
Aggregate
No. % by mass litre/m3
1 Very wet sand 7.5 120
2 Moderately wet sand 5.0 80
3 Moist sand 2.5 40
4 Moist sand /crushed rock 1.25 to 2.5 20 to 40

3. Durability of concrete:

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

S.No. Environment Exposure condition

1 Mild • Concrete surfaces protected against weather or aggressive

conditions, except those situated in coastal area.
• Concrete surfaces sheltered from severe rain or freezing
whilst wet.
• Concrete exposed to condensation and rain.
2 Moderate • Concrete continuously under water.
• Concrete in contact or buried under non-aggressive
soil/ground water.
• Concrete surfaces sheltered from saturated salt air in
coastal area.
• Concrete surfaces exposed to severe rain, alternate
wetting and drying, or occasional freezing whilst wet or
3 Severe severe condensation.
• Concrete completely immersed in sea water.
• Concrete exposed to coastal environment.
• Concrete surfaces exposed to sea water spray, corrosive
fumes or severe freezing conditions whilst wet.
4 Very Severe • Concrete in contact with or buried under aggressive
subsoil/ground water, concrete exposed to alternate
wetting & drying.
• Surface of members in tidal zone.
5 Extreme • Members in direct contact with liquid/solid aggressive
chemicals.

110
 The severity level in the water resources works may be assumed moderate to
severe only, except in such environment which is associated with corrosive fumes or
where the concrete work is to be in contact with or buried under aggressive sub-soil
/ground water.

4. Workability of concrete:

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

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

5. Mixing:

Concrete ingredients shall be mixed thoroughly in the mechanical mixer and the
mixing shall be continued until there is a uniform distribution of the ingredients and the
mass is uniform in colour and consistency. Minimum mixing time shall be 2 minutes or as
determined by the Engineer-in-charge. The accuracy of the measuring equipment shall be
within ±2 percent of the quantity of cement being measured and within ±3 percent of the
quantity of aggregate and water being measured.

6. Transporting:

Concrete shall be transported from the mixer to the form work / site of placement
as quickly as possible by methods, which shall prevent the segregation and maintain the
requisite workability. Transportation of concrete in ordinary open tippers or trucks shall
not be allowed as it causes segregation. Transit concrete mixers can be used for
transportation. Self loading, batching, mixing & transporting mixers can also be used both
for mixing and transporting concrete.

7. Placing:

The concrete shall be placed and compacted with vibrators (Immersion / needle)
and plate vibrators in case of lining before initial setting of concrete commences and shall

111
 not be subsequently disturbed. Methods of placing shall be such as to avoid segregation.
Strict and meticulous care shall be taken to avoid displacement of reinforcement or
movement of form work and concrete. Concrete shall be fully worked around
reinforcement and in the corners of form work. Over vibration resulting into bleeding of
concrete shall be strictly avoided. Spare vibrator shall be kept by the contractors as stand
by. Temperature of concrete, as placed, shall preferably be restricted to about 32ºC (90ºF).
8. Curing:

Curing shall commence as soon as possible after concrete is placed and initial set
has occurred but before it has hardened. Curing with water shall be continued for at least
14 days. Exposed surfaces of concrete shall be kept continuously in a damp / wet condition
by pounding or by covering with a layer of sacking, canvas, hessian, or similar materials
and kept continuously wet for 14 days.

9. Sampling and strength of designed mix concrete:

Sampling of concrete:

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

The minimum frequency of sampling of concrete of each grade shall be in

accordance with the following:

Quantity of concrete in the

Number of samples Remarks
work, m3
Upto 50 One set of 3 samples
One additional set of 3 sample for each
51 and above
additional 50 m3 or part thereof.

At least one sample shall be taken from each shift.

Test specimen:

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

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 Acceptance criteria of compressive strength:

The concrete shall be deemed to comply with the strength requirement when both the
following conditions are met, as per IS: 456-2000:
(a) The mean strength determined from any group of 4 non-overlapping consecutive test
results complied with the appropriate limits in columns 2 of the following table.
(b) Any individual test results complied with the appropriate limits in column 3 of the
following table.

Table: Characteristics compressive strength compliance requirements

Mean of the group of 4 non-
Specified overlapping Individual test results in
grade consecutive test results in N/mm2
N/mm2
1 2 3
≥ fck + 0.825 x established standard
deviation (rounded off to nearest
≥ fck – 3 N/mm2 or above
M15 0.5N/mm2)
Or
2
fck + 3 N/mm whichever is greater.
≥ fck + 0.825 x established standard
deviation (rounded off to nearest
M20 ≥ fck – 4 N/mm2
0.5N/mm2)
Or
fck + 4 N/mm2 whichever is greater.

In the absence of established value of standard deviation the following value may be
assumed in the first instance and there after established values based on the requisite number
of test results.
Grade of concrete Assumed standard deviation
M10 and M15 3.5 N/mm2
M20 and M25 4.0 N/mm2

fck = Characteristic compressive strength of 150 mm cube at 28 days in N/mm2. For

M10 concrete, fck is 10 N/mm2.For M15 & M20 grades, fck is 15 N/mm2 and 20 N/mm2
respectively. For World Bank aided packages for example in A.P-III works, in respect of CC
lining with a minimum cement level of 250 Kg/m3 is proposed and minimum fck envisaged is
13.5 N/mm2. Based on the assumed standard deviation values of 2 N/mm2 and 2.5 N/mm2 for
M10 and M13.5 respectively their acceptance criteria of compressive strength can envisaged
as;

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 Mean of the group of 4
Individual test results in
on-overlapping
Specified grade N/mm2
consecutive test results
in N/mm2
≥ fck + 0.825 x established ≥ fck – 2 N/mm2
M10
standard deviation.
M13.5 (CC lining with ≥ fck + 0.825 x established ≥ fck –2.5 N/mm2
minimum cement level of standard deviation.
250 Kg/m3)

Note: The minimum cement level of 250 kg/m3 for plain cement concrete lining is from the
durability consideration.
Standard Deviation: It is calculated from the following equation:
Sd =√(( X̅̅̅ -X)2/N-1)
N = No. of samples (30 samples are generally considered)
X = Sum of the mean value of 3 test specimens of each sample divided by the number of
samples, viz. overall average strength.
X̅̅̅ = Difference between overall average strength and the mean strength of 3 test specimen
of each sample.

14.2 CONSTRUCTION JOINTS & TECHNIQUE OF GREEN CUTTING

14.2.1 CONSTRUCTION JOINTS

Concrete shall be placed in massive structures in lifts which are generally maximum
of 1.5 m high. To develop proper bond between the lifts, the concrete surface shall be
freed of all laitance, coating stains, defective concrete and all foreign material and the
surface shall be roughened. This can be achieved by green-cutting. For lining work the
construction joint where ever required is to be adopted as per the sketch in Annexure –III.

14.2.2 GREEN CUTTING

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

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 d) Slump

The air-water jet will remove the thin surface film of laitance and grout to expose clean
surface.

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

14.2.3 SKILL OF JET OPERATOR :

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

14.2.4 PROPER AIR-WATER GUN :

In addition to the skill of the operator, a proper air-water gun in also a vital
requirement for effective green-cutting. The issuing nozzle must be about 460 mm (18
inches) long to ensure the requisite cutting force close to the concrete surface. A dimensioned
sketch of air-water gun is enclosed as Annexure - IV.
14.2.5 QUANTUM OF COMPRESSED AIR AND WATER :

For effective green-cutting, it is essential that the air pressure should be around 6.33
to 7.03 kg/cm2 (90 to 100 lbs. Per square inch.) It should not be allowed to fall below 90 lbs.
per square inch. The water pressure, of course, should be sufficient to bring the water into
effective influence of the air pressure. As an approximate estimate, the quantity of
compressed air required by the green-cutting gun is 2 cubic meters per minute (70 cfm) and
the quantity of water 60 gallons (273 liters) per minute.

14.2.6 SAND BLASTING :

Sand blasting is the process of roughening and cleaning the surface of old and set
concrete by means of coarse sand and air applied under pressure of 90 to 100 pounds per
square inch (6.33 to 7.03 kilograms per square centimetre) through a nozzle, so as to erode

115
the laitance and grout from the old and fresh concretes monolithic. Sand blasting of rock is
also done so that concrete may be placed on or against a clean surface as required according
to specifications.
There are two types of sand blasting namely “wet sand blasting” and “dry sand
blasting”. In wet sand blasting water is also used along with sand and air under pressure,
while in the latter, only sand and air under pressure are used. Normally the concrete and rock
surface etc., are wet sand blasted to keep down the dust.

The percentages of different sizes of sand particles for efficient sand blasting shall be
as follows.

Size Percentage
8 mesh per inch (25.40 millimetres)….. 26
16 mesh per inch (25.40 millimetres)….. 30
30 mesh per inch (25.40 millimetres)….. 23
50 mesh per inch (25.40 millimetres)….. 21

For effective sand blasting it is essential that pressure of air should be between 90 to 100
pounds per square inch (6.33 to 7.03 kilograms per square centimetre). If pressure falls below
90 pounds per square inch (6.33 kilograms per square centimetre) sand blasting becomes
ineffective. If sand having large percentage of fines is used, it will not provide the requisite
cutting power and the whole effort goes waste. A good quality well graded “sand – blast
sand” is needed for achieving the objective of sand blasting.

14.2.7 ADMIXTURES
(IS 9103 : 1999)

There are different types of Admixtures which are as follows:

1. Accelerating Admixture.
2. Retarding Admixture.
3. Water reducing Admixture.
4. Air entraining Admixture.
5. Super plasticizing Admixture.
In areas of heavy, congested reinforcement and poor accessibility, pumping of concrete
becomes inevitable and takes longer time without the process of pumping. The concrete mix
is to be designed with high workability, generally the slump of 60 mm. specified in the
agreement is not at all sufficient. Further at high cement, air entrained concrete becomes
sticky and difficult to flush. But as per A C I report concrete with a slump greater than 190
mm. that remains cohesive without excessive bleeding and segregation or abnormal

116
retardation is known as flowing concrete. Flowing concrete is useful for pumping because it
reduces pumping pressure and increases both the rate and distance that the concrete can be
pumped.

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

With the usage of Super-plasticisers in the pipe concrete, the workability of concrete is
considerably increased and the period of time that the concrete is to be placed and compacted
is well sufficient. The surface finish of the concrete is very smooth without honey-combing.
The concrete produced with the usage of super-plasticisers is dense and impermeable.

The admixture product may also be marked with standard mark of BIS. The performance
of admixture is evaluated by comparing properties of concrete with the admixture under test
with those of concrete without any admixture.

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

14.2.8 A) FOR FOUNDATION

DO’S DO NOTS
1. Verify dimensions and foundation 1. Do not forget to compare capacity of
levels as per drawing. actual soils met with design strength.
2. Wet the foundation surface to a depth 2. Don’t lay the foundation concrete
of 150 mm or to impermeable without wetting the surface.
material .
3. Ensure the rock surface free from oil, 3. Do not lay the concrete under water
objectionable coating unsound and over slush.
fragments .
4. Check-up correct batching of 4. The minimum mixing time should not
ingredients. be less than 2 min.
5. Check the batch of cement and its 5. Do not forget to keep stand by
make. vibrator and needles.

6. Check-up water cement ratio and 6. Do not place concrete in raw in

slump test. sufficiently heavy to wash mortar
from concrete.
7. Ensure uniform mixing. 7. Don not forget to cast the cubes.
8. Ensure proper compaction with 8. Do not allow segregation of concrete
vibrators and keep stand-by vibrator

117
 and needles.
9. Operate Immersion type vibrators 9. Do not use unsatisfactory mix.
nearly in vertical position to vertical
drain.

10. Cure with water for 28 days. 10. Don’t allow admixtures which will
harm the strength of concrete.
11. Compact with suitable bedding
materials in case of over excavations
and with M-5 grade concrete in case
of rock.
12. Allow admixtures as per I.S 9103-
1979.

B) SUPER STRUCTURE
1. Check the form work. 1. Avoid abrupt surface irregularities.
2. Apply cement slurry after cleaning 2. Do not deviate from specified
the surface at vertically joints. dimensions of cross section from -6
mm to +12 mm.
3. Clean and cover with a layer of 10 3. Do not allow concreting until all form
to 15 mm thick mortar of the same work installation of items to be
proportion of concrete mix for embedded and preparation of surface
horizontal joints. involved are approved.

4. Place the concrete at temperature

between 15° C to 30° C
5. The concrete shall be discharged
with half an hour after introducing
of the mix water and cement.

C) REINFORCED CEMENT CONCRETE SLABS (IS CODES 2502, 1786)

DO’S DO NOTS
1. Check the reinforcement as per 1. Do not pass without proper cover
drawing.
2. Provide asphaltic pad and water 2. Do not allow less lengths in over laps
stopper as per drawing

118
 14.3 PREPARATION OF SUB-GRADE FOR C.C. LINING
(IS CODE : 2720, 4701, 3873)

14.3.1 PREPARATION OF SUB-GRADE

Preparation of sub-grade is a factor on which depends much of the successfully

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

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

Preparation of Sub –Grade consisting of Earth :

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

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

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

4. All compaction in other than predominantly sandy reaches should be done at optimum
moisture content in layers not more than 15 cm thick to obtain a dry bulk density of not less
than 95 percent of the density at optimum moisture content. Compaction of sub-grade
depending upon the position of sub-soil water level shall be carried out in accordance with I.S
3873 – 1966 (Insitu cement concrete lining in canals).

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

119
6. All along the canal alignment, the rain cuts on the inner slopes of the Banks shall be filled
up with approved soil and shall be compacted thoroughly to required lines, dimensions and
levels.

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

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

Sub-grade density and Moisture Control :

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

Preparation of Sub Grade consisting of Rock:

The Sub-grade should be prepared and dressed true to level and according to the
required cross-section of the canal. All excavation including over-breaking below lines of
underside of lining should be filled completely upto the lines of the underside of lining with
suitable material. Viz., spalls lean concrete or gravel and aggregate. The bed may be
compacted with rollers and sides with rammers to form a firm backing for the lining. Care
should be exercised in selecting refill material for use over fractured rock of rubbles because
of the danger of washing of fines into the sub-grade voids and thus loosing support.

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

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

Criteria for fixing the thickness of CNS layer:

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

deformation. The permissible deformation is 2 cm.

2. Guidelines for choosing the CNS material should be as per IS 9451: 1995

120
In respect of the provision of CNS layer in the bed, it shall be as worked out from the
consideration of swelling pressure. However the thickness of CNS layer to be provided on
slopes shall, in addition, be governed b y the construction consideration viz., from rollable
width consideration for achieving effective compaction.

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

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

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

(m3/sec)
Swell Pressure Swell Pressure

50 - 150 KN/m2 More than 150 KN/m2

1.4 – 2.0 (50 to 70 cusecs) 60 cm 75 cm

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

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

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

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

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

KN/m2

50 to 150 75 cm

150 to 300 85 cm

300 to 500 100 cm

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

Specification of CNS Soil

121
 (i) Gradation of C.N.S Soil
1. Clay (less than 2 microns) – 15 to 20 %
2. Silt – ( 0.06 mm – 0.002 mm) – 30 to 40%
3. Sand (2mm – 0.06mm) – 30 to 40 %
4. Gravel (Greater than 2 mm ) – 0 to 10 %

(ii) The CNS material shall be non-swelling, with a maximum swelling pressure of 10
KN/m2 when tested in accordance with IS 2720 (Part-41) – 1977 at optimum moisture
content over dry condition and minimum cohesion

(iii) Index Properties :

Liquid Limit. Less than 50% but greater than 30 %

Plastically Index Less than 30% but greater than 15%.

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

Note: During construction, it shall be ensured that:

i. Serrations/steps/benches shall be provided in the side slopes of canal in cutting to

provide a good bond between the CNS layers and expansive soil and to also prevent
contact slides between CNS materials and expansive soil.
ii. Proper moisture shall be added to CNS material and expansive soil.
iii. CNS material shall be laid in layers (20 cm thickness) and compacted to requisite
proctor density, preferably, by Power Roller.
iv. To avoid slipping and rain cuts during the rainy season, it shall be advisable to
provide CNS right up to the ground level.
v. The sub grade on which CNS layer is to be laid shall, generally, be not kept exposed
for more than 4 days prior to the placement of CNS layer.
vi. Effective compaction of sub grade for side lining on slopes is very important in
cutting or embankments. In addition to the designed thickness of CNS, 20 cm or more
(perpendicular to side slope) of extra thickness (called proud) shall be provided and

122
 compacted. This proud shall be removed only just prior to the placement of lining (a
time interval of, say, about one day), thus making a fresh and well-compacted surface
available for bedding. In small section channels, it shall be appropriate to over
excavate the section, and fill the entire section with CNS material (laid in successive
layers and compacted to 98% proctor density), and, thereafter, scoop this section to
the designed section for placement of lining. This PAD method ensures effective
compaction by 8-10 T power rollers or equivalent power vibratory rollers. The CNS
material so scooped out is utilized in the next reach through re-handling.
vii. To avoid slipping and rain cuts during the rainy seasons, the CNS shall be provided
right up to ground level in cutting reaches.
viii. Under drainage arrangement, as per provisions in the agreement.

SUB-GRADE DENSITY AND MOISTURE CONTROL:

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

Lining Preparation of Sub-grade

DO’S DO NOTS
1. Check the model section to the canal 1. Do not allow concrete lining on loose
profile i.e., bottom or lining. sub-grade.
2. Check the canal profile with reference to 2. Do not allow any root of stumps to be
model sections. on sub-grade.
3. Remove roots and stumps completely from 3. Do not allow lining in expansive soils
the sub-grade. without treatment with C.N.S soils.
4. Compact over excavation in soils with 4. Do not place the porous plug below the
gravel duly wetted. surface of the lining.
5. Compact over excavation in rocky area 5. Do not allow lining without wetting the
with gravel spalls and aggregate spalls and sub grade suitably.
aggregate duly wetted.
6. Provide treatment with C.N.S soils in
expansive soils i.e., 0.6 mtrs., thick for
discharge upto 50 cusecs.

123
 7. Provide porous plug of size 375 mm long x
100 mm dia in each panel with local filters
of graded metal and sand size 600 x 600 x
750 mm.
8. Provide longitudinal and transverse drain
of size 600 x 750 mm filled up with graded
metal and sand as per drawing.
9. Check whether porous plugs are freely
draining or not.
10. Note down December water table for
providing longitudinal drains and other
relief measures ( as per drawing)

14.4 C.C. LINING

(I.S. CODES 383,269, 2116, 456, 516)

14.4.0 PROCEDURE FOR EXECUTING CONCRETE LINING

(I) GENERAL:

i) The area shall be cleared of the objectionable material, before taking up lining work.
ii) Center line, bed-width, inner & outer slopes etc. With the due provision for proud
cutting shall be marked before start of trimming or bed excavation.
iii) The excavation for trimming for preparing base for lining, i.e. sub grade shall be
carried out / - (trimmed prior to lining) and to the profile. Trimming should not be
exposed much before the actual starting of the lining of the work so as to preserve the
O.M.C. in soil which comes in contact with cement mortar layer of the lining. Over
cutting shall be avoided. However, over excavated portion shall be filled up with
suitable material, moisture and compacted to the required density by tamping, rolling
or slope compactor so as to form properly compacted sub-grade to receive the concrete
for lining.
iv) Check the profile of sub-grade so prepared and also check and record the density and
the moisture content of sub grade. All loose materials on sub grade shall be removed
and compacted suitably if required, by slope compacters.
v) In case where rocky strata is met with over excavation shall have to be carried out as
specified and shall be filled up with the selected material and compacted as per
requirement.
vi) Necessary under drainage arrangements shall be provided.

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(II) Mechanized Lining:

i) The thickness of un-reinforced in situ cement concrete lining (M15 grade) to be

provided in the main canals, branch canals, majors, and minors is indicated in the
drawings.
ii) Paver machine (Cylinder forming type) used for lining consists of conveyer belt, paver
and foot bridge.
iii) Temporary rails on wooden sleepers are laid of movement of conveyor belt and paver
assembly. It is therefore very important to maintain the line and levels of the rails to
achieve the required uniform thickness of concrete, proper placement, compaction,
finishing and maintaining profile. As such, wooden sleepers shall be provided at closer
interval of nearly 0.50 m for ensuring firm fixation of rails. Level shall be marked on
jacks of the paver to achieve the desired uniform thickness of concrete.
iv) Behind the roller, an attachment for inserting PVC strip Joint /chatter for cutting groves
are provided. Similar attachment for providing transverse joints at 4 m c/c is also
attached. In case of PVC strips the position of transverse joints at maximum @ 4 m c/c
shall be marked and the fin of longitudinal joints shall be cut to accommodate the
transverse joint at the crossings.
v) A work bridge is also provided to follow the movement of paver for attending to the
finishing of concrete and working of labours during lining, operation and subsequently
for application of curing compound.
(III) Materials :

i) Cement either OPC or PPC to be used shall be got tested in advance. Cement older than
90 days shall not be used without retesting and prior approval of Engineer-in-charge.
Daily consumption record for cement shall be maintained in cement Account books.
ii) Fine Aggregate: Sand shall confirm to the requirement of IS: 383-1970 and other
relevant specifications. Sand shall be tested for gradation, specific gravity, water
absorption, fineness modulus, spectrographic analysis etc. It should be brought from
approved quarry / Source with requisite F.M. of 2.4 to 3.0 or as specified.
iii) Coarse Aggregate:
a. Coarse aggregate for concrete shall be clean, hard, dense, free from vegetation it-
shall be confirming to IS: 383 -1970 or the specification concerned with the work.
Predominately flaky and elongated aggregate shall not be used. Gravel / metal shall
be brought from the approved source / quarry only and shall be tested for their

125
 gradation, specific gravity, water absorption, impact and abrasion values, soundness,
spectrographic analysis, flakiness and elongation.
b. Each grade of material ranging from 40 mm to 4.75 mm shall be stacked separately.
iv) Water: Potable water free from any other deleterious material shall be used. Water shall
be got tested as per relevant standards.
v) Admixture: Air entraining agent (AEA) as an admixture shall be added to the concrete
batch as per the dose prescribed in the mix-design. (Normally 200 ml/cum of concrete).

(IV) Manufacturing of cement concrete :

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

(V) Transporting, Placing & compaction of Concrete :

i) Concrete manufactured shall be handled from the place of mixing to the place of
deposit as rapidly as practicable by use of transit mixers in agitating conditions or
suitable placers and placed in final position within the specified time. Alternatively,
mobile "Self Loading, weight-batching & mixing and transporting concrete mixture (of
± 2.5 m3 drum capacity)" viz. visibly moving B & M plant can be deployed.
ii) During placement segregation of concrete should be avoided.
iii) Before placing of concrete, sub-grade shall be moistened adequately.
iv) Concrete shall be placed directly to the final position and shall not be allowed to flow.
v) Manual placing of the concrete shall not be permitted. Suitable means to convey the
concrete shall be provided to avoid free fall of concrete from the unacceptable height or
angle.

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 vi) Cutting grooves or inserting PVC strip, for longitudinal and transverse joints shall be
attended as per the requirement.
vii) The surface of the concrete finished and vibrated shall be even, smooth and free from
pockets, projections, honey combing and other objectionable defects.

(VI) Curing of Concrete :

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

(VII) Testing of concrete :

i) Concrete shall be tested for workability (slump and air content), at B.M. Plant & / or
site, cubes shall be cast at site / B.M. Plant specified.
ii) Concrete shall be tested at site and in Laboratory on representative sample collected at
site during laying in accordance with relevant specifications. Sampling procedure,
frequency and preparation of test specimens etc. shall be followed as per the relevant
specification.
iii) Test strength of samples shall be compared and evaluated as per the provisions
contained in the specifications.
iv) Concrete shall be accepted as per the acceptance criteria laid down in the relevant
specification.

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 v) Cores from the hardened concrete shall be taken to check the thickness, density, water
absorption compressive strength etc.
vi) Necessary in-situ density test of green concrete shall be taken & recorded.
vii) Records to be maintained

14.4.1 CONCRETE CORES FROM CANAL LINING AND OTHER STRUCTURES

A specimen to be tested for strength shall not be removed from the structure until the
concrete has become hard enough to permit its removal without disturbing the bond between
the mortar and the course aggregate. In general the concrete shall be 28 days old before the
specimens are removed. Specimens that show abnormal defects or that have been damaged in
removal shall not be used. (IS:457-1957).

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

TEST OF DRILL CORES:

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

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

The cores should be inspected for:

1. Segregation
2. Honey combing and
3. Thickness of lining

The cores should be tested for

1. Density (g/cc)
2. Compressive strength and
3. Water absorption.

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 A standard test cylinder has a diameter one-half of its height viz., the Length (L)/
Diameter (D) ratio is 2. However, the cores taken from in-situ-lining shall not have these
relative dimensions and consequently L/D ratio will not be 2. Accordingly, the test strengths
of these cores should need to be corrected. The curve in Attachment be used to correct the
indicated strengths so that they will be comparable with those obtained from standard
specimens. The equivalent cube strength of the concrete shall be determined by multiplying
the corrected cylinder strength by 5/4. The correction factor can also be determined from the
curve on page 13 of I.S.: 516 - 1959. (curve enclosed as Annexure-VI). The cores should be
properly stacked in sheds.

Complete data and test results of cores should be meticulously recorded. It should include.
• Location of test core (chainage: bed and side slope lining panel).
• Grade of concrete mix, maximum size aggregate of insitu-lining, slump, W/C ratio.
• Density of standard specimen prepared and cured in laboratory.
• Density of test core (g/cc).
• Thickness of lining exhibited by the test core.
• Compressive strength of test core.
• Corrected compressive strength (as per curve of Attachment A) in kg/cm
• Water absorption in percentage.
• Remarks-visual observations on any honey combing/segregation viz. lack of
consolidation be recorded.
Separate quality audit team shall review the results of tests performed on materials by
the Quality Control staff and for some tests got conducted through TSERL-, Hyderabad/NCB
and CSMRS laboratories, New Delhi. In addition, the Audit shall also review.
Data on aggregate grading (daily data, month wise), preferably computer printouts.

Grading curves for aggregates, preferably computer printouts, slump data of various
grade of concrete mixes at the batching and mixing plants and corresponding placement sites
(daily data, month-wise). Preferably computer print outs.

Data on quality characteristics of cement being procured from various cement plants.
Test reports of water samples.

The above review will facilitate the Quality Audit Team in making correct assessment
of the quality of inputs.

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Acceptance Criteria:- IS 456 : 2000

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

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

Moisture Conditioning :

Test specimens shall be completely submerged in water at room temperature for 40 to

48 hours immediately prior to the compression test. Specimens shall be tested promptly after
removal from water storage. The testing shall be done in accordance with the guide lines laid
down in I.S.: 516-1959 complete data and test results of cores should be meticulously
recorded as per format enclosed (Annexure – VII).

DO’S DO NOTS
1. Check the canal prism and verify the 1. Do not allow the concrete over loose
bed levels. sub-grade.
2. Check the gradation analysis of fine 2. Do not allow lining without wetting
and coarse aggregate to the sub-grade.
requirement of mix at batching plant. 3. Do not allow C.C lining manually
3. Allow the ingredients of fine and without vibration.
coarse aggregate as per required mix 4. Do not allow segregation of concrete
by weigh batching. while laying through discharge
4. Check the calibration of weighing conveyor.
machine at batching plant. 5. Do not allow concrete directly on
5. Check the water meter and its sub-grade from transit mixer.
discharge. 6. Do not form contraction joints over
6. Check the batch of cement, its make longitudinal drains.
and test results. 7. Do not fill up contraction joints with
7. Check the water cement ratio and sealing compound without cleaning
record the slump. with air water jet or sand blast.
8. Check whether any retarders and air 8. Do not allow any projections or
entertaining agents are added. contraction joint over the surface of
the lining.
9. Maintain load register. 9. Do not allow C.C lining without
applying suitable primer to sides,
10. Record the No. CC cubes cast and its 10. Do not remove the channels
compressive strength. immediately before setting of C.C.
11. Cure CC Lining with water for 28 11. Do not use untested cement.
days.
12. Ensure smooth surface with paver 12. Do not allow to sink the porous
roller passes. plugs in the drains.
13. Form the contraction and 13. Do not allow lining without making
construction joints as per approved proper arrangements for curing with
drawing. water.
14. Check the thickness of C.C Lining 14. The Co-efficient of variation in the
for each panels. compressive strength of cement
15. Checking placing of mastic pad at should not be more than 8%.
structures of construction joints.

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 16. Allow concrete lining at temperature
between 150C and 300C.
17. Check periodically the coefficient of
variation in the compressive strength
of cement.
18. The batching plant to be used shall
confirmed to the required of IS 4925-
1968.

14.5 SHOT– CRETING AND GUNITING

(IS 9012 : 1978)

INTRODUCTION

Shotcreting has been referred initially as guniting .

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

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

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

14.5.1 PURPOSE OF GUNITING

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

14.5.2 PURPOSE OF SHOTCRETING

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

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 Careful guniting ensures long service life of structures. However it is essential to observe
several precautions at every stage in order to obtain the desired results and durable
structures.

14.5.2(a) Materials for Shotcreting :

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

14.5.2(b) Sand:

Sand for Shotcrete shall comply with the requirements of IS 383-1970 and graded evenly

from fine to coarse as per Zone II and Zone III grading of IS 383-1970. Well graded sand

as per either of the following grading can be used.

SAND

IS Sieve Designation Percentage by mass passing for

Grading – I Grading - II
10
10 mm 0 100

4.75 mm 90 – 100 90 – 100

2.36 mm 75 – 100 85 – 100

1.18 mm 55 – 90 75 – 100

600 micron 35 – 59 60 – 79

300 micron 8 – 30 12 – 40

150 micron 0 – 10 0 - 10

Sand should be free from deleterious substances and organic impurities.

14.5.2(c ) Coarse Aggregate:

The coarse aggregate when used shall comply with the requirements of IS 383-1970. It shall,
generally conform to one of the gradings given in the following table

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IS Sieve Percentage by mass passing for aggregate of Nominal maximum
Designation Size
(mm) 10 mm 12.5 mm 20 mm
25 mm - - 100
20 mm - 100 90-100
12.5 mm 100 90-100 -
10 mm 85-100 40-70 20-55
4.75 mm 10-30 0-15 0-10
2.36 mm 0-10 0-5 0-5
1.18 mm 0-5 - -

14.5.2(d) Water: Ordinary potable water with pH value not less than 6 and not more than 8.5 will
be used.

14.5.2(e) Chemical Additives:

The following additives be used in the concrete mix in the ‘Dry Mix Process’
of shotcreting

Sodium Carbonate = ½ Kg per 50 Kg bag of cement

Sodium Aluminate = ½ Kg per 50 Kg bag of cement
Calcium Carbonate = 1 Kg per 50 Kg bag of cement

14.5.2(f) Shot –Crete Mix:

The water – cement ratio should be maintained within the range of 0.35 to 0.50 by mass.
Normally the following mix proportions would be adequate.

Sl.No Ingredients Used Convential Mix Design with

Shotcrete Mix Admixture
1 Cement 450 kg / m3 420 kg / m3
2 Sand 1100 kg / m3 1050 kg / m3
3 Coarse aggregate (5 mm – 10 mm 500 Kg/m3 420 kg / m3
size)
4 Water Cement Ratio 0.42 0.4
5 Admixture (if any used) - 21 kg (Apcocrete shot-P)
6 Mix Proportion 1:2.44:1.11
7 Compressive Strength after 28 days > 25 N/mm2 51 N/mm2

Conventional Shot Crete Mix Proportion was obtained from NSP QC Manual
• Short Crete Mix Design with Admixture was obtained from the Mix Design Report
issued by JNTU Hyderabad for Jurala-Lift Irrigation Project.
14.5.3 Shotcreting Process

The two basic shotcreting processes are:

a) Dry mix process, and

b) Wet mix process.

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Dry-Mix Shotcrete: Pneumatically conveyed shotcrete in which most of the mixing water is
added at the nozzle

Wet-Mix Shotcrete: Shotcrete wherein all ingredients, including mixing water are mixed in
the equipment before introduction into the delivery hose, it may be pneumatically conveyed
or moved by displacement.
Comparison of features of Dry-Mix and Wet-Mix Shotcrete Processes

Dry-Mix Process Wet-Mix Process

1. Mixing water instantaneously 1. Mixing water controlled at plant

controlled at the nozzle by operator and measured at time of batching
to meet variable field conditions
2. Longer hose lengths, if necessary 2. Normal pumping distances
necessary
3. Limited to accelarators as the only 3. Compatible with all ordinary
practical admixture admixtures. Special dispensers for
addition of accelarators are
necessary.
4. Use of air-entraining admixture not 4. Air entraintment possible.
beneficial. Resistance to freezing and Acceptable resistance to freezing
thawing is poor. and thawing.
5. Intermittent use easily accommodated 5. Best suited for continuous
within prescribed time limits. application of shotcrete
6. Exceptional strength performance 6. Lower Strengths, similar to
possible conventional concrete
7. Lower Production rates 7. Higher Production rates

8. Higher Rebound 8. Lower rebound

9. Equipment maintenance costs tend to 9. Equipment maintenance costs tend

be lower to be higher
10. Higher bond strengths 10. Lower bond strengths, yet often
higher than conventional concrete

SFRC : Steel Fibre Reinforcement concrete is also used for stabilisation in application such
as slopes or tunnelling, where it is find difficulty to use conventional steel mesh

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14.5.4 Do’s and Donot’s in shotcreting

DO’S DONOT’S

1. Exposed reinforcement bars be 1. All oversize pieces shall be rejected by

cleaned free of rust / scales. screening, since they are likely to cause
Additional reinforcement be provided plugging of the hose
if and as warranted.

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

5. It is recommended that surfaces be

kept continuously water cured
for atleast 7 days.

14.5.5 Quality Control For Shot – Creting

1. During the Shot-Creting operation, both the Construction and Quality Control Staff
should continuously inspected the site to check the materials, Concrete mix, Shotcreting
equipment, application of shotcrete and curing.
2. The finished surface should be sounded with a hammer for detection of any hollow
pockets due to lack of bond. If any such hollow pockets or other defects are found,
they are to be carefully cut out and replaced with the new shotcrete layer. The first

135
 layer is also to be sounded with a hammer and remedial action taken for any hollow
pockets before commencing the application of the final layer.
3. Cubes or cores shall be taken from the panels for testing. The cores shall have a
minimum diameter of 7.5 cm and a length-diameter ratio of at least 1, if possible. The
specimens shall be tested in compression at the age of 7 or 28 days or both.
4. The cut surfaces of the specimens shall be carefully examined and additional surfaces
shall be exposed by sawing or breaking the panel when it is considered necessary to
check the soundness and uniformity of the material. All cut and broken surfaces shall
he dense and free from laminations and sand pockets.
5. The test panels are fabricated by gunning on to a back form of plywood. A
separate panel shall be fabricated for each mix design being considered, and also
for each gunning „position to be encountered in the structure, that is, slab, vertical
and overhead sections. At least part of the panel shall contain the same
reinforcement as the structure, to show whether sound shotcrete is obtained behind
the reinforcing rods. The test panel shall be large enough to obtain all the test
specimens needed, and also to indicate what quality and uniformity
may be expected in the structure. Generally the size of panel shall
be not less than 75 x 75 cm. The thickness shall be the same as
in the structure except that it shall normally be not less than 7-5
cm.
6. The steel fibre reinforced concrete (SFRC) has gradually taken over
conventional shotcrete. Traditional reinforcement shotcrete is
steel/wiremesh, fixing this mesh totally by manual work and it
proceeds at a slow pace.

136
 Typical plant layout for wet mix positive displacement equipment

14.6 TUNNELING
(IS 4880, 5878 (Part4 &6),15026)
Tunnels can be defined as underground passes made without removing the over lying
rock or soil. Water conductor system occasionally takes the form of tunnels through high
ground or mountains, in rugged terrain where the cost of surface pipe line or canal is
expensive and elsewhere as convenience and economy dictates.
The most commonly adopted method of tunnel excavation in India is the conventional
drilling and blasting method. And other method is by Tunnel Boring Machine.

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14.6.0 UNDERGROUND EXCAVATION
Drilling and Blasting

DRILLING

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

BLASTING

Explosives - High explosives are used for tunnelling operations. The strength of high
explosives is expressed as a percentage of the strength of blasting gelatine.

Types of explosives used in tunnelling operations:

a) Blasting gelatine - It has the highest concentrated power and it is used for blasting very
hard and tough rocks.

b) Special gelatines 90 percent to 40 percent - These are characterised by gelatinous

consistency, high density, freedom from noxious fumes and good storage properties. The
requisite strength of gelatine may be selected to suit the actual rock conditions which may
vary from very hard to soft rock. For use at high altitudes, low freezing types of gelatines
may be used.

c) Ammonia dynamite-These types of explosives contain equal amount of nitroglycerine

and nitrate of ammonia. They are made in strengths from 15 to 60 percent. They are not so
sensitive or so quick and shattering as straight dynamite. They are recommended for soft
rock.

d) Semi-gelatine - They contain nitrate of ammonia, gelatinised nitroglycerine and nitro-

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

i. Full face attack : In this method the entire cross sectional area of the Tunnel to be

138
 excavated is attacked simultaneously. This is generally recommended for small size
Tunnels.
ii. Top Heading and Benching: In this method the Top Heading is excavated first. The
benching is removed slowly. This is suitable for a very less cross sectional area or
where rock is not of good quality. This method is most commonly used.
iii. Bottom Heading and Stopping : In this method Bottom Heading is made first and
overhead stop is removed later, suitable when section is large.
iv. Drift Method : In driving a large tunnel is may be economical to drive a small tunnel
called drift or a pilot tunnel prior to excavating the full face.
14.6.2 SEQUENCE OF OPERATION FOR CONSTRUCTION OF TUNNELS
i. Marking tunnel profile
ii. Setting up of drilling jumbos and drilling of holes.
iii. Loading the drilled holes with explosives and blasting.
iv. Defuning and ventilating tunnel.
v. Checking misfires if any.
vi. Scaling the loose material.
vii. Removal of the muck.
viii. Guniting, Rock bolting and Erection of support system and lining if and when
necessary.
Minimum Excavation Line (A-Line)
A Line within which no unexcavated material of any kind and no supports other than
permanent structural shall be permitted to remain.

Pay Line (B-Line)

An assumed line (beyond A-Line) denoting mean line to which payment of excavation
and concrete lining is made whether the actual excavation falls inside or

139
outside

General Aspects for design in Tunnel lining:

Lining in tunnels technically an important component therefore lining operation requires

considerable study and careful planning

• Study of Geology of rock mass

• Results of insitu tests for modulus of elasticity
• Effective Cover, Poissons Ratio, State of stress
• Seepage & Presence or Absence of Ground Level water table
• Cavitations
Loading Conditions

Design shall be made for “Normal” Loading Conditions & Shall be checked for Safety
under “Extreme” Loading. The design loading shall be as follows:
a) External Rock Load
b) Self Load of Lining
c) External & Internal Water pressure
d) Grout Pressure
e) Other Loads
To provide a proper bond between concrete and rock surface, grouting is recommended.

140
Types of grouting

a) Contact grouting b) Consolidation grouting

It may be worthwhile to mention here that systematic investigation and instrumentation give
a lot of information before hand which could long way to solve many of the varied
tunnelling.

14.7 MASONRY

I.S CODES 1597, 1812, 1200, 383, 269, 2116

DO’S DO NOTS
1. The stone shall be of uniform colour, 1. Do not use stones other than granite of
texture, strong, hard durable. crushing strength less than 1000
2. Dress C.R.S. stone to a depth of 75 mm kgs/sq.cm..
on all four sides. 2. Do not allow bushing more than 40 mm
3. Wet the stones before placing in position on the face.
clear and cover with fresh mortar. 3. Do not allow stones of length more than 3
4. Place stones in layers to the line and times the height.
plumb. 4. Do not allow stone of breadth less than
5. Provide weep holes at 2 mtrs interval height of ¾ of thickness of wall.
staggered as per drawing. 5. Do not allow breaking of vertical joints
less than 75 mm.
6. Chisel dress the corner stones. 6. Header shall not project not less than 10
cm beyond stretcher.
7. Face stones shall be laid alternately in 7. Do not place stone in position without
headers and stretchers. clearing and wetting.
8. Provide bond stones at 2 mtrs. Interval in 8. Do not allow skin stones, weathered
each layer and mark. stones.
9. Place the hearting stones on its broadest 9. Do not place stone in position without
face. wetting.
10. Ensure perfect hearing to make the 10. Smaller stones shall not be placed in
masonry lower cores.
11. Mortar shall be used within 30 min. after 11. Joints thickness should not be more
discharge from mixer. than 12 mm.
12. Sieve analysis for sand shall be done 12. Do not allow mixing less than 3
periodically which confirm to minutes for through mix.
I.S Sieve % of passing
Designation
4.75mm 100
2.36mm 90 to 100
1.18mm 70 to 100
600 micron 40 to 100
300 micron 5 to 70
150 micron 0 to 15
13. For flush pointing the mortar shall be
finished off flush and level with edges of 13. Do not add more water than required
the stones. to have a consistency of 90 to 130 mm.

141
14. Joints shall be raked out to minimum 14. Avoid spreading of mortar over the
depth of 12 mm when the mortar is surface of the masonry.
green.
15. Cure the masonry with water for 2 15. No pointing to be commenced
weeks. without washing and wetting the joints
16. Cure the plastered surface with water for thoroughly.
14 days.
17. Cure the pointing surface with water for
7 days.

14.8 REINFORCED CEMENT CONCRETE SLABS

(IS CODES 2502, 1786)

DO’S DO NOTS
1. Check the reinforcement as per 1. Do not pass without proper cover
drawing.
2. Provide asphaltic pad and PVC water 2. Do not allow less lengths in over laps.
stopper as per drawing.

REGISTERS TO BE MAINTAINED

1. Load Register.
2. Cement Day Book
3. Sieve analysis for sand and metal
4. Slump for consistency
5. Compressive strength of concrete.

TESTS TO BE CONDUCTED

1. Sieve analysis for fine aggregate (field test).

2. Sieve analysis for coarse aggregate (field test)
3. Slump test (field test)
4. Compressive strength of concrete (Lab test)

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 14.9 GROUTING

(I.S. 11293 (Part 2) 1994 & I.S. 6066 : 1994)

14.9.0 SCOPE
The pressure grouting of rock, masonry, concrete dams with cement and withor
without suitable admixtures and fillers applicable to general grouting, consolidation grouting,
and curtain grouting shall broadly confirm to Indian Standard, IS: 6066-1994.
GENERAL
A. The design requirements for adopting a grouting programme are as under. The parameters
will depend on the type of structure.
(a) Curtain Grouting:

i. To safeguard the foundation against erodibility hazard, and / or

ii. To reduce quantity of seepage.

(b) Consolidating grouting.

i. To reduce the deformability of jointed or shattered rock.

ii. Grouting the masonry dams to minimize seepage.
B. To reduce Quantity of Seepage:

a. For dams exceeding 30 m height, curtain grouting should be carried out when the
water absorption exceeds one lugeon.
b. For dams under 30 m, height, curtain grouting is to be carried out where the water
absorption exceeds 3 lugeon.

C. The depth, spacing and orientation of grout holes are to be related to the geological
features; for example, inclined holes should be preferred when the rock permeability is
primarily due to closely spaced vertical/ sub-vertical system of joints. It is sometimes
necessary to evolve a pattern of holes consisting of different sets of holes appropriate to each
type of discontinuity, such as bedding planes, system of joints and lava contacts.

14.9.1 GROUTING METHODS:

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

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FULL DEPTH GROUTING:

In the full depth method each hole shall be drilled to the full desired depth, washed,

pressure tested and grouted in one operation. This method shall be usually limited to short

holes, 5 m or less in depth, or holes upto 10 m that have only small cracks and joints with no

risk of surface leakage. In deep bore holes high grouting pressures shall be used to achieve

proper penetration of the grout at a spacing of holes shown in the drawing or directed by the

engineer-in-charge. As full depth grouting involves the risk of disturbance in the upper

elevations, it is not generally considered suitable for grouting deep holes. For grouting in

heterogeneous strata, where the nature of rock discontinuities is subjects to large variations in

relation to the depth, full depth grouting shall not be used and stage grouting shall be

preferred to packer grouting in such cases.

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

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

14.9.2 PATTERN AND DEPTH OF HOLES AND SEQUENCE OF GROUTING

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

14.9.3 PATTERN OF HOLES FOR CURTAIN GROUTING

SINGLE LINE GROUT CURTAINS
Single line grout curtains are effective only in rocks / masonry / concrete having a
fairly regular network of discontinuities with reasonably uniform size of openings. In such
cases a curtain of adequate width can be achieved by grouting a single line of holes. In

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

14.9.4 PATTERN OF HOLES FOR CONSOLIDATION GROUTING

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

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 When it will be desirable to test the efficacy of consolidation grouting by comparing
the grout absorption in primary and secondary holes a rectangular or square pattern of holes
shall be preferred. This shall be the case when the joints are irregular and relatively free from
in filling or it is not necessary to remove the materials filling the joints.

14.9.5 SEQUENCE OF GROUTING

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

14.9.6 GROUT MIXTURE

Masonry/Concrete grouting is usually performed with a mixture of cement and water with or
without additives.

The cement generally used shall be any of the following:-

i. Ordinary Portland - IS: 269-1989 or
- IS: 8112 -1989 or
- IS: 12269-1987
ii. Portland Pozzolana - IS: 1489
(Part-I)-1991
(Part-II)-1991
iii. Portland Slag - IS: 455- 1989

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iv. Super Sulphated cement - IS: 6909-1990
iv. Sulphate Resisting Portland - IS: 12330 -1988

14.9.7 DRILLING AND GROUTING EQUIPMENT

DRILLING EQUIPMENT

The equipment shall be capable of drilling holes of size 38 mm to 75 mm diameter to the

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

14.9.8 GROUT EQUIPMENT

The equipment for mixing and grouting shall be capable of effectively mixing in
correct and specified proportions, agitation the grout and pumping to into the holes, in an
uninterrupted flow at the designated pressure it into the holes, in an uninterrupted flow at the
designated pressure upto at least of 5 kg/cm2 (75 psi) - 7 kg/cm2 (100 psi). There should be
satisfactory arrangements for accurately measuring the quantity of water, cement and other
ingredients to be used. The agitator shall have paddles of suitable design and shape to keep

148
the mix in proper consistency till it is pumped into the holes. Standard equipments of
approved quality shall be used.
The mixing and conveying system shall be laid to provide sufficient capacity for a
heavy flow of grout. The mixer shall be in two compartments or parts so that grout could be
mixed one when that from the other is being pumped. In general an uninterrupted flow of
grout shall be maintained and the grout conveyed from the pump to the hole through a pipe.
The mixer shall be placed as near the hole as possible and long pipe lines avoided.
The flow of grout into the holes shall be controlled by the pressure relief valve by passing
and returning to the mixer all grout not accepted by the hole at the desired pressure.
Proper pressure gauges shall be provided to measure the pressure of the grout pumped
into the hold. They shall be provided with diaphragms to prevent grout from getting into the
gauges and clogging them.

14.9.9 CIRCULATION SYSTEM

The circulation system required two pipe lines, a supply line from the grout pump to
the grout hole and a return line from the grout hole to the agitator/pump. By opening the
supply and grout hole valves, grout is forced into the hole as required. Pressure is maintained
by adjusting either the supply valve or the return valve, or both, so that complete control of
pressure is maintained at the hold. There should be a pressure gauge at the delivery end of the
pump. No grout is wasted when washing out the grout lines and close control of the grouting
operations is maintained. When directed electric or diesel drive pumps shall be employed, use
of a return line is necessary. Long supply lines shall be avoided to reduce the chances of
change in consistency of the grout and clogging. Field telephones are useful for
communication between the pump operator and the grout man at the collar.
The circulating system shall be so provided that the grout shall be kept circulating
continuously at sufficient velocity to prevent settlement of cement or clogging of pipe line
and fittings. The pump and the pipe line shall be flushed with clear water at frequent
intervals, to keep them clear. Deposits of grout in the pump, mixer etc. not removed by
flushing shall be removed, scraping, clipping etc. A fine screen capable of being readily
removed, cleaned and replaced would be desirable between the mixer and the pump. Proper
arrangement shall also be provided with equipment to stock adequate quantity of cement,
stone dust etc. likely to be required for the grouting.
After the grouting operations are completed for shift on the day, the remaining unused
grout mix shall be thrown away. Also a mix not used up completely within one hour after
mixing or that which in the opinion of the Engineer has set or clogged shall be thrown away.

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At no extra cost to the development. No payment shall be made on account of such wasted
labour, material etc.

14.9.10 DRILLING THE GROUT HOLES

In such area as may be designated, holes shall be drilled size 38 mm to 50 mm in dia.
These will be spaced in rows spaced 3 meters apart or as specified in the drawings. The holes
specified for coring and exploratory drilling / test holes shall be of 75 mm diameter or as
directed by the Engineer-in-charge.
Drilling in masonry, concrete or combination of these for local drainage or shallow
grouting shall also be done by percussion tube drilling method and paid for under the same
item as for the above. Grout holes both in the masonry or concrete shall be of varying depth.
The drilling in masonry or concrete above will be paid for at the same rate as for as drilling in
rock.
All holes will be drilled with the equipment of the type specified most suitable for the
particular job as approved by the Engineer-in-charge.
The depth and requirements of the drilled holes indicated are approximate and may be
altered as per actual needs, as found necessary.
The grout holes shall be drilled normal to the surface of masonry, or if so directed
inclined to the normal upto any inclination, in the direction as may be indicated without any
extra cost.
At locations, where the leakages are excessive, masonry might require additional
drilling and grouting of any area which may have earlier been drilled, grouted and even
covered by concrete or masonry. The contractor shall comply with directions in this behalf.
The unit rate for all such holes also be the same as quoted in the bill of quantities and shall be
paid separately.
Re-drilling required, if any, in case of incomplete holes because of the contractors
failure to clean the hole before the grout has set or for any other reason shall be performed at
the contractors expense. Where the grout has been allowed to set as per specific directions or
approval of the Engineer-incharge the required re-drilling shall be paid for at 25% of the
tendered rate of drilling grout holes.
After the drilling of the grout hole has been completed it shall be temporarily capped
or plugged until it is grouted. Any hole that gets checked before it is grouted shall be opened
to the satisfaction of the Engineer-in-charge by and at the expense of the contractor.

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

14.9.12 PRESSURE GROUTING

The proportion of cement and water will be as determined by the Engineer-incharge.
Cement and water shall be of the same quality as specified under section IC sub- section A &
D. Payment shall be made for the quantities of material actually used as assessed by the
Engineer which shall be final and binding. The grout shall be applied at a low pressure (as
may be specified by the Engineer) initially and gradually but within the time as may be
specified by the Engineer, increased upto the maximum pressure. It shall be maintained for
minimum period of about 10 minutes thereafter. Care shall, however, be taken to release the
pressure immediately should there be signs of any movement of any part or heaving of rock /
concrete / masonry, which amongst other observations, be indicated by sudden and erratic fall
in pressure.

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 When grouting has just been commenced in any hole, if it is found that the grout has
been freely flowing too far to fast from the hole at low pressure, fine stone dust, or other
suitable material as may be approved by the engineer shall be immediately be added in order
to block the leakage at sufficient distance from the hole and thus localize the area to be
grouted for any particular hole or set of holes. As a hole approaches refusal the grout shall be
progressively thinned and grouting operation continued to refusal at the specified maximum
pressure maintained for period of minimum 10 minutes as stated in above paragraph.
The consolidation grouting of the foundations shall be done at pressure upto 5 kg/cm2
or as directed by Engineer-in-charge.
Utmost care and precautions shall be taken to ensure that the dam masonry or
concrete is not damaged during the grouting. Any damage caused to the concrete or masonry
or any other element, material or structure in the dam or adjacent to it shall be made good by
the contractor at his own expenses and to the satisfaction of the Engineer-in-charge.

14.9.13 METHOD OF APPLYING GROUT

It is always advisable to begin with a low initial pressure say 0.10 to 0.25 kg/cm2/m of
overburden, and build-up the pressure gradually. Initially the rate of intake may be 20 to 31
lit/min. In order to avoid the premature build-up of high pressure a general guideline should
be followed that the pressure should be raised only when the intake rate falls below 5 lit/min.
When surface leaks develop, pressure should be immediately reduced. Sub-surface cracking
may sometimes be indicated by an abrupt rise in the rate of intake after grouting at a constant
value of pressure for a considerable period.
Grout mixture (ratio by weight of water and cement ranging from 5:1 to 0.8:1 are
recommended. It is only in exceptional circumstances that mixtures leaner that 10:1 need be
used. The choice of grout mixtures may be based on results of percolation tests conducted
prior to grouting.

The grouting of hole shall be continued till the hole or a combination of holes
takes grout mix at a rate less than -
Rate of grout intake Time in Minutes Pressure
0.03 cum. (1 cft.) 20 3.5 kg/cm2 (50 psi or less)
0.03 cum. (1 cft.) 15 3.5 kg/cm2 to 7 kg/cm2
(50 to 100 psi)
The grouting shall, however be stopped when the pressure gauge registers sudden rise
or when other indications are seen of extension or upheaval or rock / masonry / concrete,

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under the pressure being applied. After the hole has been grouted it should be closed by
means of a valve to maintain the grout under pressure in the seams or crevices into which it
has been forced.
After any hole is grouted, it should be examined if cement has settled, unduly with
water coming up, the amount of settlement depending on the proportion of mix used. Holes,
where such settlement has taken place, are to be cleaned of all soft sediment and grouted
again under pressure.
Shallow grouting (i.e. grouting not exceeding 15 m in depth) operations shall always
be started on the side of pattern so that the trapped air may be more easily forced out.
Grouting shall be continued until at the specified pressure the hole refuses to take
grout more than specified above. If for any reasons grouting operations must be stopped
before a hole has been grouted to refusal, clear water shall be kept running into the hole until
grouting is resumed.

14.9.14 TEST FOR GROUTING WORK

To test the efficiency and penetration of grouting, fresh holes shall be drilled as
directed by the Engineer-in-charge, after the grouting operations are completed to determine
post grouting permeability values. These holes shall be tested by water under pressure actual
to the maximum grout pressure adopted at the particular location and the amount and the rate
of leakage if any measured in each such hole. If the Engineer-in-charge so directs, such holes
shall be grouted at pressure specified by the Engineer. If not they shall be left open. No extra
payment will be made for testing the holes by water. If such holes are grouted under direction
Engineer, such grouting will be paid for as ordinary grouting on the basis of the quantity of
cement and stone dust (where used) actually forced in. Cost of drilling of such holes shall be
paid under the appropriate item of drilling.

14.9.15 RECORDS
The information to be recorded daily is as follows:-
i. Result of the pressure test;
ii. Grouting feature, for example, curtain and consolidation;
iii. Date
iv. Shift
v. Name of Foreman
vi. Grouting method, packer grouting or full depth grouting and stage whether first,
second or third;

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

14.9.16 REPORTS
In order to facilitate control and planning of grouting operations, reports should be
prepared at regular intervals to summarize important observations and data. It serves no
useful purpose to maintain elaborate records unless they can be complied in such a form that
significant trends can be determined regarding the efficacy or otherwise of the grouting
operations. In the absence of such reports timely action, would not be possible and
procedures which may be ineffective or unsuitable may be continued indefinitely. These
reports may consist of:
a. a hole-wise register of drilling, water tests, routing and inter connections.
b. for consolidation grouting -a plan showing grout hole stages and grout intake.
c. for curtain grouting - a 'L' section showing driving stages and grout intake.

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14.9.17 GROUTING MUST BE DONE IN THE PRESENCE OF THE ENGINEERIN-
CHARGE OR HIS REPRESENTATIVE
Whenever pressure grouting is to be done, the contractor will give due notice thereof
to the Engineer-in-charge to enable him or his authorized representative to be present during
the grouting operations which will always be done in his presence.

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

14.9.19 CALIBRATION OF PRESSURE GAUGES & WATER METERS ETC.

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

14.9.20 MEASUREMENT AND PAYMENT

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

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14.9.21 Test Grouting:
Test grouting of atleast 10% if the holes already grouted shall be carried out to ensure
that no gap/void/cavity remains unfilled. The holes with high consumption of grout during
initial grouting and those with high water intake but less consumption of grout shall be
specially included for test grouting along with other holes.

Daily Records of Grouting Operations :

Daily Records of grouting operations along with the approval of Engineer incharge,
shall be maintained as specified in I.S. Codes.

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 CHAPTER-XV

PRESSURE MAIN (MS PIPES)

(IS 228, IS 3803,IS 1916 and IS 3589)

In the recent years and currently the government has taken up many Lift irrigation
schemes. The water conductor system in a LI scheme is mainly through pipes. These pipes
generally are manufactured in a yard, near to the reach of pipe laying. The pipe is
manufacture by welding plates which form number of longitudinal and circumferential weld
joints. Later these pipes will be transported to a site and joined by welding after placing in the
position to form the pipe line. So the pipe in the yard and pipe line at the site should be tested
to verify the leakage.

Further the plate itself may have manufacturing flaws and to detect such flaws the material
and the effectiveness of welding has to checked. Such detection is carried using a
radiography test or ultrasonic pulse velocity test as per the frequency prescribed in the
agreement. Before laying the pipe line, the BM stones/pillars shall be fixed in CC and DCBM
register shall be approved by the Engineer-In-Charge.

• The welding is carried out by approved procedure by competent operators and the
welding is ground smooth to the correct nominal thickness.
• Cage reinforcement of Guniting shall be minimum as per IS 432(Part-I) or IS
432(Part-II )codal provisions.
• Compressive strength of concrete used for coating i.e, Guniting shall be 25N/mm2 at
28 days
• The Elco meter is used for verifying the epoxy coating thickness
• One Field joint out of 10 joints is to be tested.
• All dents more than 2% of outside diameter shall be removed
• Over the ground saddle support and anchorage has to be provided.
• Minimum reinforcement in the guiniting shall be 3% of the quantity of steel cylinder
of minimum plate thickness as per IS 1916.

15.0 HYDROSTATIC TESTING

Hydrostatic Testing means the use of water for pressure testing a pipeline to determine its
integrity
Pressure tests are performed to ensure the safety, reliability, and leak tightness of pressure
systems. A pressure test is required for a new pressure system before use or an existing

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pressure system after repair or alteration.
There are two methods for pressure tests
1. Hydrostatic: Each steel cylinder shall be subjected to Hydrostatic test, before
concreting as per IS Code 1916: 1989 is performed by using water as the
test medium.

2. Pneumatic: A Pneumatic test uses air, nitrogen, or any non-flammable and non- toxic
gas. Pneumatic tests are potentially more dangerous than hydrostatic because of the
higher level of potential energy. Pneumatic tests may be performed only when at least
one of the following conditions exists:
1. When pressure systems are so designed that they cannot be filled with
water.
2. When pressure systems are to be used in services where traces of the
testing medium cannot be tolerated.
15.0.1 HYDROSTATIC TEST PROCEDURE
1. Ensures the pressure gauges used have current calibration stickers.
2. Remove pressure relief valves or non-reclosing relief device from the vessel or test
boundary where the test pressure will exceed the set pressure of the valve.
3. Holds down each valve by means of an appropriate test clamp and pressurizes both
sides of non-reclosing relief devices.
4. Installs temporary, higher-rated devices where practical Installs the calibrated test
gauge so it is visible at all times.
5. Ensures the skillet blanks or test plugs or clamps are appropriate for use and are free
of obvious defects.
6. Fills and vents system as necessary to remove as much air as practical.
7. Ensures that water used for the test is at not less than ambient temperature, but in no
case less than 70°F.
8. Pressurizes the system, raising the pressure in the system gradually until the
designated test pressure is achieved.
9. Maintains this test pressure for 10 minutes before inspection. Then, if test is above
maximum allowable working pressure (MAWP), reduces to MAWP while making a
full thorough inspection for leaks.
10. Ensures the metal temperature at the time of the hydrostatic test does not exceed
120°F.
11. If there is evidence of structural distortion, either rejects the system or repairs as
advised by the inspector.
12. If there is leakage in the system, Ensure for repairs or Rejects the system.
13. When the test is completed, vents the test pressure to atmosphere and returns relief
devices to normal configuration.

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 14. Maintain a pressure test record.

Each section of the Steel Pipe line(including bends fabricated for field erection) Shall be
tested under hydraulic Pressure equal to 1.5 times design pressure however pressure for
hydrostatic tests, shall not exceed(i.e Pressure computed by the following formula straight
pipes and bends:
P= (Yp * T) / R
P = Test Pressure in N/mm2.
Yp = Yield Point Stress of Steel used in the Particular
Coarse under test in N/mm2
T= Actual Minimum Wall Thickness of Pipe in “mm” in
the Pipe Length tested.
R= Internal Radius of Pipe in “mm”
Each pipe shall be completely filled with water and Pressure shall be slowly and
uniformly increased until the required test pressure is reached. The test pressure shall be
applied and released THREE TIMES successively and after each application shall be held
steady, for at least 15 Minutes or till such time until all welded joint and plate can be
examined for defects, leaks etc. Any defects in welds or plates disclosed by the hydrostatic
test shall be repaired by the Contractor to the satisfaction of the Engineer-in-Charge. All
repaired sections shall be again tested for Hydrostatically.

15.0.2 LEAKAGE TEST

This will be conducted by filling the pipeline with water from intake with the suitable
types of valves in the pump house closed. All the field joints and the expansion joints gland
packing shall be tightened with in permissible limits. If necessary, measures to prevent
leakage at other location will be taken by the Contractor.

Do’s & Do Not’s

Sl.No Do’s Sl.No Do Not’s
1. Check for Pressure Gauges current 1. Do not allow if current Calibration
Calibration report or stickers. report or stickers are not available.
2. Remove pressure relief valves or 2. Do not deviate from the specifications
non-reclosing relief device from the
vessel or test boundary where the
test pressure will exceed the set
pressure of the valve.
3. Check that each valve is holds
down by means of an appropriate
test clamp

159
4. Check for the calibrated test gauge
is visible at all times
5. Check that water used for the test is
at not less than ambient temperature
6. Check the metal temperature at the
time of the hydrostatic test does not
exceed 120°F
7. Maintain Proper test record

HYDRO TESTING OF FIELD JOINTS

Name of Work :__________________________________________

Date of Testing :_______________

Joint No. From :________________to____________

Chainage From :________________ to____________

Test pressure :__________________

Remarks
Reading observed in
Time (Retention (if any leakage is identified, write
Sl.No. Pressure gauge
Period) location/
(Kg/cm2)
joint ID)

From To

Calibration certificate No.:________________ Validity till:______________

Pressure guage No. :________________

Test Begin Date :________________ Time:____________

Test End date :________________ Time:____________

Contractor AEE DEE EE AEE DEE EE

Construction Construction Construction QC&I QC&I QC &I

160
 VISUAL INSPECTION OF WELD IN FIELD

Date of Inspection:_____________

Visual Inspection
Joint Fit
Sl.No. Chainage Pipe No. Inside Outside Remarks
No. up
welding welding

AEE DEE EE

QC&I QC&I QC&I

15.1 ULTRASONIC TESTING (UT)

IS 13311 (Part 1)

It is a Non-destructive testing techniques based on the propagation of ultrasonic

waves in the object or material tested. In UT applications, very short ultrasonic pulse-waves
with centre frequencies ranging from 0.1-15 MHz, and occasionally up to 50 MHz, are
transmitted into materials to detect internal flaws or to characterize materials.
A common example is ultrasonic thickness measurement, which tests the thickness of
the test object, to monitor pipe work corrosion.

Ultrasonic testing is often performed on steel and other metals and alloys, though it
can also be used on concrete, wood and composites.

Ultrasonic waves are introduced into a material where they travel in a straight line and
at a constant speed until they encounter a surface. At surface interfaces some of the wave
energy is reflected and some is transmitted. The amount of reflected or transmitted energy
can be detected and provides information about the size of the reflector. The travel time of the
sound can be measured and this provides information on the distance that the sound has
travelled.

161
15.1.1 Ultrasonic inspection techniques
1. Pulse-echo and Through Transmission:
Relates to whether reflected or transmitted energy is used
2. Normal Beam and Angle Beam:
Relates to the angle that the sound energy enters the test article
3. Contact and Immersion:
Relates to the method of coupling the transducer to the test article

Note: IS Code 4260: 2004 recommended practice for ultrasonic testing of butt welds in
ferritic steel.
Ultrasonic testing and inspection of welds by direct contact pulse echo reflection
method. This method is applicable to material thickness over 5 mm.

Do’s & Do Not’s

Sl.No Do’s Sl.No Do Not’s

1. Check for the device is having the 1. Do not allow if the required
required frequency. frequency is not available.
2. Check for the technique and use for 2. Do not deviate from the
the appropriate material. specifications
3. Check that ultrasonic instruments
and probes shall be capable of
being used without difficulty in the
temperature range of – 10 to +
50°C.
4. Check that screen height linearity
shall be measured and recorded in
accordance with IS 12666.
5. Check for ultrasonic apparatus shall
be adjusted for sweep range and
calibrated prior to inspection as
described in IS 12666
6. Check the temperature difference
between the examination and the
calibration block surfaces shall be
within 14°C
7. Check for nominal frequency shall
be in the range of 2 to 5 MHz.

162
 15.2 RADIOGRAPHY
(IS 1182)
Radiography is an imaging technique that uses electromagnetic radiation other than
visible light, especially X-rays, to view the internal structure of a non-uniformly composed
and opaque object (i.e. a non-transparent object of varying density and composition).

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

generator and is projected toward the object. A certain amount of X-ray is absorbed by the
object, which is dependent on the particular density and composition of that object. The X-
rays that pass through the object are captured behind the object by a detector (either
photographic film or a digital detector). The detector can then provide a superimposed 2D
representation of all the object's internal structures.

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

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

Note: Is Code 1182-1983 (Reaffirmed 2000 recommended- practice for radiographic examination
of fusion welded butt joints in steel plates

15.2.1 RADIOGRAPHIC TECHNIQUES

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

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

WELD SURFACE PREPARATION

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

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

IMAGE QUALITY INDICATORS

Image quality indicator sensitivity is a means by which the quality of radiographic techniques
used may be compared and is not a measure of Saw sensitivity as the latter is a complex
function of the geometry, absorption and location of the flaw.

163
IDENTIFICATION OF RADIOGRAPHS
Each section of weld radio graphed shall have suitable
symbols affixed to it to identify
a) The job or work piece,
b) The joint,
c) The section of the joint,
d) Manufacturer’s name or trade-mark,
e) Date.
MARKING
Permanent marking for the work piece shall be used to provide reference points for accurate
relocation of the position of each radiograph.

15.2.2 TECHNIQUES FOR MAKING RADIOGRAPHS

Films and Screens
Cassettes
Alignment of Beam
Interception of Undesirable and Scattered Radiation
Source-to-Film Distance/Focus-to-Film Distance
Size of Area Examined
Density of Radiograph
X-ray Tube Voltage and Type of Gamma-Ray Sources
Processing
Viewing
15.2.3 RECORD OF TECHNICAL DATA
Each radiograph or set of radiographs Information shall be available on the radiographic
technique used. In particular the following shall be recorded:

• Type of X-ray equipment, tube voltage and current or type of radioactive source
together with its strength and size;
• Time of ‘exposure, type of film and screen, and focus-to-film distance/source-to-film
distance;
• System of marking used; and 4 position of IQI, whether source side or 5lm side.

Do’s & Do Not’s

Sl.No Do’s Sl.No Do Not’s
1. Check for the Sensitivity for 1. Do not adopt if the sensitivity
adopting Technique-“A” or deflects.
Technique-“B”

164
2. Check that in technique-B only 2. Do not allow if fine-grained films or
fine-grained films or ultra-fine- ultra-fine-grained films and lead
grained films and lead screens are screens are not used.
used.
3. Check that technique-B is exposed 3. Do not deviate from the
for long duration time. specifications
4. Precautions are taken to protect the
radiographer when X-ray equipment
or radioactive sources are in use.
5. Check that the position of the weld
can be identified on the radiograph.
6. Ensure unequivocal identification of
the section on radiography.
7. Check in separate radiographs of
the joint should overlap at least 10
mm to ensure that no portion of the
joint remain unexamined.

165
 CHAPTER – XVI

USAGE OF MANUFACTURED SAND, GEOSYNTHETICS AND CONCRETE

CANVAS HYDRO

16.0 MANUFACTURED SAND

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

The IS 383-1970 code of aggregates defines the types of fine aggregates as

1. Natural Sand

2. Crushed Gravel Sand

3. Crushed Stone Sand

The IS code clearly specifies that the crushed gravel sand and crushed stone sand can
be used in concrete. The size of the crushed gravel sand and crushed stone sand shall be
within the range of 2.36mm to 4.75mm.

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

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

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

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

166
16.1 GEOSYNTHETICS

The construction of embankments on soft soils can be a challenging task. In this context, the
use of geo-synthetics to improve embankment stability is one of the most effectives and well-
tried forms of the soil reinforcement technique.

Geosynthetics can be effectively used to:

1) Reduce soft soils displacements due to low bearing capacity of soft soils

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

3) Prevent sliding failure along the geosynthetics surface.

167
 The efficiency of geosynthetics as reinforcements of embankments on soft soils can
be visualized by the following figures.

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

Note: Usage of Geosynthetics shall be referred to the Chief Engineer, Central Designs
Organisation for approval and adoption

16.2 CONCRETE CANVAS HYDRO

Concrete Canvas Hydro is a revolutionary new containment product from

Concrete Canvas Ltd. It combines concrete impregnated fabric technology with a high
impermeability, chemically resistant geomembrane backing. The geomembrane provides
a high performance liner with a testable joint for quality assured containment
applications. The liner incorporates a hi-visibility welding strip allowing joints to be
thermally bonded with a twin or triple track air channel for on-site testing. The flexible
concrete impregnated fabric, hardens on hydration, to provide long term protection to the
geomembrane from puncture, abrasion, weathering and UV degradation. This hard

168
 armour concrete surace effectively removes the need for concrete, soil or aggregate top
cover, normally required with conventional liner systems.

Concrete Canvas Hydro can be laid directly onto existing profiles without loss of
volume capacity for refurbishment projects, providing significant overall time and cost
savings.

Concrete Canvas Hydro provides effective weed suppression eliminating the ongoing
maintenance cost of soil covered systems. CC Hydro also reduces the end-of-life costs
associated with treatment of any contaminated top cover.

Concrete Canvas Hydro has been shown to have excellent resistance to a wide range
of chemical reagents, including hydrocarbons, digestates and acidic leachates.

Concrete Canvas Hydro can be rapidly unrolled to provide a high impermeability

ditch, flume or canal lining for drainage, irrigation or hydroelectric schemes; providing
flow characteristics similar to smooth concrete(manning’s=0.011) and abrasion resistance
more than double that of standard concrete(OPC)

Note: Usage of Concrete Canvas Hydro shall be referred to the Chief Engineer, Central
Designs Organisation for approval and adoption

169
 CHAPTER – XVII

FREQUENCY OF TESTING

Sl. Test Frequency of Test Purpose Test Designation

No
1. Grain size analysis for One test per day/for every To know the As per IS-2720-IV-
classification 3000Cu.m classifications of 1975
soil actually put in
the embankment
2. Atterberg Limit test One test per day -do- IS-2770-V-1970
3. Specific Gravity One test per day -do- IS-2720-III-1964
4. Field Density and One test for every 1500 m3 of To determine the IS-2720-XXVIII-
Moisture content earth work and atleast one placement density 1974
test in each layer laid on and moisture IS-2720-XXIX-
embankment. content. 1966
IS-2720-XXXIII-
1971
5. In-situ permeability One test in one week or every To determine IS-2720-XVII-1966
Test 3m of embankment height or permeability
for 20,000 m3 characteristics of the
fill material
6. Triaxial Shear Test One test in one week or every To know the shear IS-2720-XII-1975
3m of embankment or for characteristics of fill
30,000 m3 material (in-situ)
7. Consolidation Test 1 set of 3 samples in every To know the IS-2720-XV-1965
6m height of embankment or settlement rate and
for 30,000 m or once in ten its magnitude
days
8. Standard Proctor Test One test per day for To determine MDD IS-2720-VII-1970
individual Bonow Area and OMC of the soil
and compare the
results with
Laboratory value
9. Moisture content One test in each sample To know the IS-2720-II-1975
moisture content of
the sample
10. Shrinkage Factor One test in one week or 5 To determine IS-2720-PartVI-
mtrs of embankment height. shrinkage limited 1972
FILTERS
11. Grain Size Analysis One test for every 200 m3 of To find % of the IS-2385-Part I
filter (sand) One test for D10, D15, D30,
every 200 m3 of D50, D60 and D85
filter(Aggregate) grain sizes of
materials
12. Clay lumps and One test for every 200 M3 To find out clay IS-2386-Part II
organic impurities (sand) One test for every 200 lumps & Organic
m3 (Aggregate) impurities level

170
Sl. Test Designation
Test Frequency of Test Purpose
No
1 CEMENT

a) Chemical
a) IS : 269-1989
i) Alkalies OPC < 0.60%
b) IS : 1489-1991
ii) Minor, Major For each consignment PPC < 0.70%
c) IS : 4032-1985
oxides by Calorimetry
iii) Chloride PPC/OPC <0.05%

Not < 2250 cm2/gm

Not > 10mm
b) Physical
i) Fineness
Penetration upto 5 to
ii) Soundness (Le
7 mm from base.
Chatelier)
IT – Not <30 min
iii) Consistency a) IS : 269-1989
FT – Not >600 min
iv) Setting time For each consignment b) IS : 1489-1991
3 days – 160 kg/cm2
(Initial & Final) c) IS : 4031 1988
7days – 220 kg/cm2
v) Compressive
28 days – 330kg/cm2
Strength
PPC 7 days -
vi) Heat of Hydration
65Cal./gm
vii) Drying Shrinkage
OPC 28 days-
75Cal./gm < 0.15%

Test Allowable
Sl.
Test Frequency of Test Purpose Designation Limits
No
2 FINE AGGREGATE
To know grain 2.2 to 3.2
One Test for each
i) Sieve Analysis size and the IS : 2386 –
150 m3 of sand used
(Fineness Modules) fineness Part - I- 1963
in concrete
modules of sand
One Test for each Allowable
To Utilize the
150 m3 of sand used limit of
ii) Unit weight and data for Mix IS : 2386 –
in concrete (also bulkage of
Bulkage of sand design Part - III- 1963
once in a shift or for sand is 20 %
computation
every consignment.
One Test for each
To assess the IS : 2386 –
iii) Organic Impurities 150 m3 of sand used
quality of sand Part - II- 1963
in concrete
Loss not >
One Test for each 10% after 5
To assess the IS : 2386 –
iv) Soundness 150 m3 of sand used cycles of
quality of sand Part - V- 1963
in concrete immersion in
Na2SO4
To assess the Not > 3% for
One Test for each
silt content IS: 2386 – natural FA and
v) Silt content 150 m3 of sand used
present in the 1963 not > 5% for
in concrete
sand. crushed FA
vi) Specific gravity, One Test for each To Utilize the IS: 2386 –
Moisture content and 150 m3 of sand used data for Mix Part - III- 1963

171
 absorption in concrete design
computations

Test Allowable
Sl.
Test Frequency of Test Purpose Designation Limits
No
2 COARSE AGGREGATE
To know
One Test for each
gradation and IS : 2386 –
i) Sieve Analysis 150 m3 of sand used
percentage of Part - I- 1963
in concrete
various size
ii) Specific Gravity, Not>2.6
To Utilize the
Bulk density, One Test for each Not more than
data for Mix IS : 2386 –
Moisture content, 150 m3 of sand used 5% by weight
design Part - III- 1963
absorption & silt in concrete Not > 3%
computation
content
Loss not >
iii) Soundness One Test for each To assess the 12% after 5
IS : 2386 –
(Sodium sulphate 150 m3 of sand used quality of coarse cycles of
Part - V- 1963
method) in concrete aggregate immersion in
Na2SO4
Wearing
surfaces : Loss
One Test for each To assess the Not
iv) Abrasion, Impact IS: 2386 –
150 m3 of sand used quality of coarse >30%,Non
and crushing value Part-IV -1963
in concrete aggregate wearing
surfaces
not>45%
v) Organic One Test for each To assess the Less than 1%
IS: 2386 –
impurities(Mica 150 m3 of sand used quality of coarse
Part - II- 1963
content) in concrete aggregate
Falling in left
side of Sc/Re
Curve…Innoc
To know the
vi)Alkali reactivity IS: 2386 – uous
Twice in one innocuous or
(Alkali- Aggregate Part - VII- Falling in right
working season deleterious nature
reactivity) 1963 side of Sc/Re
of aggregate
Curve…
deleterious

To know the Deleterious

IS: 2386 –
vii)Petrographic Twice in one deleterious constituent
Part - VIII-
examination working season constituents and shall not
1963
silt in aggregate exceed 5%

172
Sl. Test Allowable Limits
Test Frequency of Test Designation
No
Gravel
i) Size of Gravel Not larger than ¾’’
1 ii) Liquid Limit For each stack IRC : 19-1977 <20%
iii) Plasticity Index <6%
Water 6 to 8
pH value, Organic, In-Organic Two sample for each IS : 3025 Part II Not > 200 mg/l
2
source IS : 3025 Part 18 Not > 3000 mg/l

Not > 400 mg/l

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

Not > 2000 mg/l

Suspended solids IS : 3025 Part 17
3 RR STONE
I) Abrasion value IS : 1124 - 1974 Not to exceed 6 %
ii) Crushing strength IS : 1124 – 1974 Granite – 1000 kg/cm2
Basalt – 400 Kg/cm2
For each quarry
iii) Specific Gravity IS : 1124 – 1974 2.60
iv) Water Absorption IS : 1124 - 1974 Not to exceed 5 %
v) Durability IS : 1124 - 1974
4 REINFORCEMENT
Weight Dia ≤ 8mm ± 4 %
Dia ≤ 8mm ± 2.5 %
Diameter
For each IS : 1786 – 1985 Dia ≤ 8mm ± 0.5 %
Ultimate Test Refer the table below
consignment IS : 432 – 1982
Strength for allowable limits.
Yield Stress
Elongation

Allowable Limits for Reinforcement Bars

Characteristic Minimum elongation

Types of strength (yield stress Ultimate tensile on gauge length of
Reinforcement of 0.2 % proof stress stress, N/mm2 5.65 X √ Cross –
N/mm2 sectional area (%)
Mild steel of grades
I 255 412 20-23
236
II 231 373 20-23
211

173
 Medium Tensile Steel 353 538 17-20
348
323
Cold worked deformed 415 15 % more than the 14.5
bars actual 0.2 % proof
stress
500 10 % more than the 12
actual 0.2 % proof
stress
Hot Rolled 412 15 % higher than the 14.5
yield stress
SAIL –MA of grades
300 HY 300 440-560 20
350 HY 350 490-610 20
410 HY 410 540-660 19

Frequency to Testing Cement Mortar, Masonry and Concrete.

Sl. Test Allowable Limits
Test Frequency of Test Designation
No
3 Tests specimens per 50
m3 of concrete subject to a
1 Cube Test for concrete minimum of three samples IS : 456-2000
per day for each grade of
concrete
Cube test for cement 3 tests per each grade of IS 2250 – 1981
2
mortar in masonry mortar per day Appendix - A
Not greater than
2.5X10 -8 mm per sec,
Permeability tests on
3 Once in a week IS : 3085 - 1965 for rich mortar &
cement mortar
4.8X10 -8 for lean
mortar.
At least two holes in every Not greater than 2.5
Permeability tests on block for every lift, one in lugeons in masonry in
4 masonry applicable for upstream and one IS : 11216 – 1985 CM 1:3 and 5 lugeons
masonry dams) downstream in staggered in masonry in CM 1:4
fashion for dams
One test in each shift on at As per Mix Design
5 Slump test frequent intervals to check IS : 1199-1959
workability

The actual frequencies shall be determined by the Engineer-in-charge to suit the

nature and variability of material placed and the rate of fill placement with the objective of
ensuring best quality control and quality construction.

174
 CHAPTER – XVIII

MONITORING THROUGH CONTROL CHARTS

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

Preparation of Quality Control Reports and Control Charts is considered to be a vital

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

STANDARD DEVIATION (I.S. 456 – 2000)

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

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

n = number of sample test results.

175
 If at least 30 test results for a particular grade of concrete at site with the same
materials and equipment are not available, the standard deviation, S, for the corresponding
degree of control, may be assumed from the following tabulation, given IS : 10262 – 2009.

Table 1: Assumed Standard Deviation (as per I.S. 10262 – 2009)

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

Acceptance Criteria for Concrete: As per IS 456: 2000

The concrete shall be deemed to comply with strength requirement when both the
following conditions are met.

a) The mean strength determined from any group of four consecutive tests results
complies with the appropriate limits in column 2 of the following table.
b) Any individual test result compiled with appropriate limits in column 3 of the
following table.

Table 2: Characteristics compressive strength compliance requirements (as per

amendment No.4 May-2013 to Table 11 of IS 456 – 2000)

Specified Mean of the group of 4 Individual test

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

176
NOTE :
1. In the absence of established value of standard deviation , the values given in the
above table may be assumed and attempt should be made to obtain results of 30
samples as early as possible to establish the value of standard deviation.
2. For concrete of quantity upto 30 m3 (where the number of samples to be taken is
less than four as per the frequency of sampling given in 15.2.2 of IS 456)the mean
of test results of all such samples shall be fck + 4 N/mm2, minimum and the
requirement of minimum individual test results shall be fck-2 N/mm, minimum.
However, when the number of sample is only one as per 15.2.2 of IS 456, the
requirement shall be fck + 4 N/mm2, minimum.

Flexure Strength

When both the following conditions are met, the concrete complied with specified

flexural strength:

a) The mean strength determined from any group of four consecutive test results exceeds the

specified characteristic strength by atleast 0.3 N/mm2 .

b) The strength determined from any test result is not less than the specified characteristic

strength less 0.3 N/mm2.

INSPECTION AND TESTING OF STRUCTURES:

Inspection:

Immediately after stripping the formwork, all concrete shall be carefully inspected
and any defective work or small defects either removed or made good before concrete has
thoroughly hardened.
In case of doubt regarding the grade of concrete used, either due to poor workmanship
or based on results of cube strength tests, compressive strength tests of concrete on the basis
of core and / or load test may be carried out.
Core Test:

The point from which cores are to be taken and the number of cores required shall be
at the discretion of the Engineer-in-Charge and shall be representative of the whole of
concrete concerned. In no case, however, shall fewer than three cores be tested. Core shall be
prepared and tested described in IS : 516-1959.
Concrete in the member represented by a core test shall be considered acceptable if
the average equivalent cube strength of the cores is equal at least 85 percent of the cube

177
strength of the grade of concrete specified for the corresponding age and no individual core
has a strength less than 75 percent.

In case the core test results do not satisfy the requirements of or where such tests have not
been done, load test may be restored to.

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

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

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

ILLUSTRATION OF PREPARATION OF CONTROL CHARTS FOR CEMENT

AND CONCRETE

A. CONTROL CHARTS FOR CONCRETE STRENGTHS

An illustrative set of compressive strength data (hypothetical data) and its further
analysis for incorporation in a typical set of control charts is shown in the enclosed Table A.
It is assumed that 3 companion specimen samples are made from each homogeneous batch
and constitute a “test”. Thirty such tests are covered in this Table A.

Master Chart

The-axis indicates the chronological order of tests (col. 1 of the Table A ). Strengths of
the individual companion specimens constituting a given “test” (Cols.2 to 4) are plotted one
above the other along the ordinate and their mean values (col.5) representing each test are
joined to generate the Chart. Refer Plate 1A.

178
Moving average strength chart

Each test is averaged with 4 number of previous tests, making a total of 5 and this
moving average , viz average of 5 consecutive tests (col 6) is plotted. Refer Plate 2A.

Range Chart

The range between the maximum 5 consecutive tests as shown in Col 7 is also plotted.
This chart monitors the overall batch to batch variation of production Refer Plate2A.

The target average strength and control limits can be estimated depending on the percentage
of test values permitted to fall below the specified or “characteristic” strength fsp in terms of
the standard deviation δ (or coefficient of variation Cv) corresponding to the degree of
control aimed at. The target average strength (TAV) is worked out as.

Fsp + 0.84 δ for mass concrete

And Fsp + 1.65 for structural concrete conforming to IS : 456

The standard deviation is what is assumed for mix design. For mass concrete
coefficient of variation Cv is assumed as 15% and the target average strength is 160+0.84 δ.

Then δ/(160+0.84 δ) = Cv 15%

Solving, δ = 27.5 kg/cm2

So, target av. Strength = 150 + 0.84 δ

= 160 + 0.84 * 2.75

= 182 Kg/cm2

Upper warning limit (UWL) = 183 + 0.84 δ(TAV + 0.84 δ)

206 Kg/cm2

Lower warning limit (LWL) = 160 Kg/cm2 (viz. fsp)

Upper Action Limit (UAL) = 183 + 3 *27.5

= 265 Kg/cm2

Lower Action Limit (LAL) = 183 - 3 δ

= 101 Kg/cm2

Lower Warning Limit = 183 + 0.84 * 27.5/√5

The control charts, incorporating these limits are exhibited in Plates 1A, 2A.

The lower action limit (LAL) shall in no case, be lower than the absolute minimum
strength wherever specified IS : 456 -1978 specifies on over riding absolute minimum of 0.8
times the characteristic concrete strength.

179
Target average range = d*6 =2.326*27.5=64

This is depicted in Control Chart 3A.

B. CONTROL CHARTS FOR CEMENT STRENGTHS

An illustrative set of strengths data and its analysis for incorporation in a typical set of
control charts is shown in the enclosed Table B. Thirty One tests (each consisting of 3
companion specimens) are covered in the Table B. The master chart, moving average
strength chart and the range chart ( range between the maximum and minimum 5 consecutive
tests) are depicted in Plates 1B, 2B and 3B respectively.

Target Av. Strength = 45 Kg/cm2

Coefficient of variation (Cv) = 8%
So, Standard deviation (δ) = 45 * 8% = 36 Kg/cm2

The Upper and lower warning

limits are set as = 450 ± 1.65 * δ

Upper warning limit (UWL) = 450 +1.65 *36

509 Kg/cm2

Lower warning limit (LWL) = 450 – 1.65 *36

391 Kg/cm2

The upper and lower limits are

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

Target average range = d * δ

d = coefficient depending upon the no. of tests considered for obtaining the range and for 5
consecutive tests, d = 2.326

So, target av. Range = 2.326 * 36 = 84 Kg/cm2

The control chart of cement test result ranges (between maximum and minimum of
consecutive tests), depicting the mean sample range (84 Kg/cm2) as well, is shown in Plate
3B.

180
 TABLE – A

ILLUSTRATIVE DATA AND ITS ANALYSIS FOR SETTING UP

CONTROL CHARTS OF CONCRETE STRENGTHS (Mass Concrete)

Location Strength of Individual Test value Moving Range bet.

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

181
STATISTICAL ANALYSIS

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

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

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

* Conc. Grade A150 S160

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

TABLE – B
ILLUSTRATIVE DATA AND ITS ANALYSIS FOR SETTING UP
CONTROL CHARTS OF CEMENT STRENGTHS

Minimum 28 days strength as per IS: 269 = 330 kg/cm2

Location on Compressive Strength @ 28 days three Average Moving Range bet.

X-axis of individual specimens of 4, 5 Avg. of 5 Max & min. 5
chart and 6 consecutive consecutive
Sr.No./Date test results test results
of Sample
1 2 3 4 5 6 7
1 500 490 495 495 - -
2 450 430 425 435 - -
3 500 480 490 490 - -
4 550 555 545 550 - -
5 415 430 415 420 478 130
6 430 430 430 430 465 130
7 400 390 395 395 457 155
8 405 425 445 425 444 155
9 440 445 450 445 423 50
10 465 435 435 445 428 50
11 445 435 440 440 430 50
12 450 410 430 430 437 20
13 505 495 500 500 452 70
14 500 495 490 490 462 70
15 465 450 450 455 464 70
16 445 465 455 455 467 70
17 465 490 485 480 477 45
18 430 445 445 440 465 55
19 445 455 465 455 457 40
20 410 430 420 420 450 60

182
 21 490 510 485 495 458 75
22 450 450 465 455 453 75
23 450 435 450 445 454 75
24 470 460 465 465 456 75
25 475 470 465 470 466 50
26 450 465 465 460 459 25
27 460 450 440 450 458 25
28 450 450 450 450 459 20
29 470 470 470 470 460 20
30 490 490 490 490 464 40
31 470 475 480 475 467 40

STATISTICAL ANALYSIS

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

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

183
 CHAPTER XIX

COMPILATION OF QUALITY CONTROL DATA.

Quality control data shall be compiled on a continuing basis and reports

prepared in a booklet form at regular intervals. These reports should include the
following :

1. Brief report of the project for which the data is compiled.

2. Index plan.
3. Geologists report depending upon the nature of the project.
4. Note on foundation treatment, grouting pattern if suggested.
5. Nature of input materials like soil, cement, aggregates, steel and their source of
supply.
6. Test reports on input materials and acceptance criteria as laid on in IS codes.
7. Design of concrete mixes.
8. Summary of records and reports on grouting as specified in I.S. 6066-1984 and IS:
9. Test reports on concrete like slump, compressive strength etc.
10. Control charts for cement and cement concrete i.e. Master charts, moving average
strength and range chart etc.
11. Statement showing the deployment of machinery.
12. Statement showing the quantity of concrete and earth work executed and number
of cube tests conducted.

184
 CHAPTER-XX

DETERMINATION OF FIELD MOISTURE AND DRY DENSITY OF

COMPACTED EARTH FILL

Name of Work: -

1. Sample No. / Date

2. Wt. of core cutter = Wc

3. Wt. of core cutter + wet soil = Ws

4. Wt. of wet soil in gms (Ws-Wc) =W

5. Wet density gms /c.c. = W / V

6. Moisture container No.

7. Wt. of container + wet soil in gms

8. Wt. of container + dry soil in gms

9. Wt. of moisture in gms (m)

10. Wt. of dry soil in gms (d)

11. % moisture content (m.c.) = m x 100 / d

12. Dry density in gms /c.c.

SIGNATURE OF A.E. /A.E.E.

185
PLATES

186
187
188
189
190
191
 PROFORMA

Test results of cement samples

Name of factory

Tested at ----------------------------------Laboratory

S.No. Particulars Values for the month of Remarks

Jan Feb Mar Apr May

1. No. of test results(n)

2. Avg. Compressive Strength

3. 3 days (Kg/cm2)

4. Standard Deviation (Sd)

Coefficient of variation (Cv%)

5. Av. Compressive Strength at 7

days(Kg/cm2)

6 Standard Deviation (Sd)

Coefficient of variation (Cv%)

7 Av. Compressive Strength at

28days(Kg/cm2)

8 Standard Deviation (Sd)

Coefficient of variation (Cv%)

192
 ANNEXURE – I

SKETCH SHOWING ROLES AND RESPONSIBILITY MATRIX

OWNER PROJECT PROJECT CONTRACTOR HAS

GOTS CONSTRUCT Q.C / Q.A. TEAM RESPONSIBILITY
TEAM FOR

Set the tone for Quality Organise for Organise for Means and methods of
Construction construction QC/QA construction to ensure
supervision supervision progress with quality.
Issue directives on firm Convene pre- Implement OK Construction
commitment to construction Card System sequencing and
quality&strict meeting with meticulously. scheduling.
implementation of QC/QA Contractor after
programs on projects. award of
Contract.
Introduce OK
Card system
Establishment project Job-specific Acquaint fully Quality control related
requirement and arrange specifications be with technical to construction
Project financing. made available to specifications in activities.
all, right to the the contract
lowest documents and
supervising level. implement
strictly.
Set organisation of field Monitor regularly Conduct sampling Site safety, first aid,
construction team. the adequacy of and testing of ambulance, house
contractors inputs and outputs keeping.
equipment and as per specified
plant for progress frequency.
& quality
Set organisation of quality Administer Calibrate the lab Strict compliance of
control team contract strictly. testing equipment technical
regularly specifications.
Enforce house
keeping and site
safety by the
contractor.
Approve training Conduct regular Aquaint fully with Filling of OK Cards
programme for construction progress & testing procedures and presenting to
supervision and quality quality review and standards. construction staff.
control personnel on QC/QC meetings with
aspects through a specialist contractor
organisation (Like/NCB)

193
Get QC labs recognised for Involve Geologist Communication and Planning and
their reliability and on geo technical feed back of deployment of
competence through a problems deficient quality construction plant
specialist organisation (Like work be very and equipment
NCB) Ensure regular prompt, work be consistent with
payment to the stopped, if necessary progress & quality.
contractor for (and construction
works done. team informed for
violation of specified
procedures by
contractor.

Constitute high level co- Ensure Fulfilling contract

ordination committee to preparation of commitments and
coordinate Quality “as built drawing competently and
management system for “as work proceeds faithfully:
QC/QA and oversee performing on
implementation. schedule.
Conduct internal Quality Encourage Compile statical Implementation
Audit of project works Contractor to get Quality Control Data contract change
yearly through CE (CDO) his nucleus on continuing basis. orders.
personnel trained This be, preferably,
in NCB / any computerised.
reputed
orgainsation on
QC/QA aspects.
Use Control Charts Constructing project
as dynamic tools to facilities as
monitor QC of specified by contract
cement/ document.
concrete/mortar.
Avoiding conflicts.

Maintain all relevant Inducting

Indian Standards experienced
booklets. supervisory
personnel on
construction.

Have close liason Maintaining

with construction photographic record
team and contractor of work.
on QC/QA aspects.

Keep abreast with

improved quality
control procedures /
equipment and
deploy the same.

194
 PROJECT DESIGN TEAM

• Furnish construction drawings well in time.

• Provide prompt advice on design and design related quality aspects.
• Review and approve job-specific technical specifications and acceptance criteria
• Inspect works regularly to ensure proper implementation of design, safety, and
quality, related aspects in construction.
• Provide guidance to project teams on technical elements of contract change orders.
• Review adequacy of contractor’s infrastructure, job facilities and construction plant
deployment to assist Owner in achieving quality construction.
• Co-ordinate with Dam Safety Review Panel/Panel of Experts and incorporate Panel
recommendations in designs/drawings.
• Maintain close liaison with Geologist.

195
196
197
198
199
200
 ANNEXURE VI

CORRECTION FACTOR FOR HEIGHT-DIAMETER RATIO OF A CORE

201
 ANNEXURE VII

DATA OF THE CORES TAKEN FROM INSITU CONCRETE CANAL LINING

Name of Canal Grade of Concrete Mix

Reach Slump

Name of the Contractor W/C ratio

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

202
203
 ANNEXURE - IX
GOVERNMENT OF TELANGANA
ABSTRACT

MINES & MINERALS - REGULATION OF SAND MINING - NEW SAND MINING POLICY,
2014 – FORMULATION OF TELANGANA STATE SAND MINING RULES – 2015 (TSSMR-
2015) - ORDERS – ISSUED

INDUSTRIES & COMMERCE (MINES-I) DEPARTMENT

G.O.MS.No.3, DATED:08-01-2015.
Read

G.O.Ms.No.38, Industries & Commerce (Mines.I) Department, Dated:12-12-

2014.
*****
The following Notification shall be published in an Extraordinary Issue of Telangana State,
Gazette dated:08-01-2015.
NOTIFICATION

In exercise of the powers conferred by Section 15(1) of Mines & Minerals (Development &
Regulation) Act, 1957 (Central Act 67 of 1957), the Governor of Telangana, in supersession of all
earlier orders issued in the composite State and in accordance with the New Sand Mining Policy-
2014 for the State of Telangana as announced in G.O.Ms.No.38, Industries & Commerce (Mines.I)
Department, Dated:12-12-2014, hereby makes the following Rules to regulate the Mining and
Transportation of sand in the State of Telangana and for the purposes connected therewith, namely:-
.

1. Short title and commencement:-

(i) These Rules may be called the Telangana State Sand Mining Rules, 2015.
(ii) It extends to the entire State of Telangana.

2. Regulation of extraction/disposal of Stream/River Sand

(i) Sand extraction and sale other than de-casting patta lands and in respect of I and II
order streams, in the State shall be through Telangana State Mineral Development
Corporation Limited (TSMDC) only.

(ii) Regulation of Stream/River sand extraction/disposal from the areas other than
falling in Schedule Areas be done by the authorities specified under Rule 3(6).

(iii) Allocation of specified sand bearing areas located partially/fully in Scheduled

Areas shall be as per the Panchayats Extension to Scheduled Areas (PESA)
Rules, 2011 or any suitable subsequent rules/amendments to be issued by
Government from time to time with Technical and Administrative support from
Integrated Tribal Development Authorities (ITDA)
/Telangana State Mineral Development Corporation Limited (TSMDC Ltd.) under
the direct supervision and control of the Agency Magistrate/District Collector
concerned. Operational guidelines shall be issued by the District Collector from time
to time.

204
3. Sand extraction in I and II order streams:
Sand extraction shall not be permitted in notified over-exploited areas except for local use in
villages or towns bordering the Streams for bonafide purposes other than commercial
operations/public trading/stocking etc. The Sand extraction:-

(1) Shall be as per Rule 23-(1) (a) of Water Land and Tree Rules, 2004 or any suitable
subsequent rules/amendments to be issued by Government from time to time.

(2) Shall be for local use:

(a) Free of cost:

(i) For weaker section housing schemes on a certificate issued by the District
Collector or any authorized officer;

(ii) For own use basing on the actual requirement to be certified by Panchayath
Secretary concerned and

(b) For local use of sand in Government works on payment of seigniorage

fee.

(3) The Panchayath Secretary of concerned Gram Panchayath shall issue way bills as
prescribed by the Mandal Authority under WALTA, 2002 or any suitable subsequent
rules/amendments to be issued by Government from time to time for the purposes
mentioned under sub-rule (2) within the jurisdiction.

(4) Transportation of sand shall be by means of bullock carts/Tractors only within the
jurisdiction.

(5) The District shall be treated as a unit for free movement of sand within the
jurisdiction.

(6) The District Collector shall put in place proper administrative mechanism for
enforcement of extraction and transportation of sand in I and II order Streams
comprising of:

a) Revenue Divisional Officer concerned.

b) Tahsildar concerned

c) Representative of Deputy Director, Ground water

Department.
d) Executive Engineer (concerned), RWS/Irrigation Dept.

e) Sub-Divisional Police Officer.

f) Motor Vehicle Inspector (concerned) from Transport Dept.

4. Constitution of Sand Monitoring Committee (SMC)

In partial modification to G.O.Ms.No.38, dated 12.12.2014, the District Collector &

Magistrate shall be the Chairman of the District Level Sand Committee. There will be a State
Level Committee with Chief Secretary of the State as Chairman.

205
 (1) Constitution of District Level Sand Committee (DLSC)
The identification of sand bearing areas in III, IV and above order streams/rivers for
extraction shall be by the District Level Sand Committee. The District Collector shall be the Chairman
of the District Level Sand Committee, other members will consist of the following officers:

(a) District Collector : Chairman

(b) Joint Collector : Vice-Chairman

(c)*Project Officer, ITDA concerned. : Member

(d) District Panchayat Officer : Member

(e) Dy. Director, Ground Water Dept. : Member

(f) Executive Engineer, Irrigation/ River : Member

Conservator.

(g) Executive Engineer, Rural Water Supply : Member

(h) Environmental Engineer, Telangana State Pollution : Member

Control Board.

(i) Nominee of Telangana State Mineral : Member

Development Corporation Ltd. (TSMDC)
: Member- Convenor
(j) Asst. Director of Mines & Geology
concerned.

206
 *In case of sand reaches falling partly or fully in Scheduled Areas.
(i) The District Collector may invite any other officer like the Superintendent of Police and
District Transport Officer as deemed fit.

(ii) The Assistant Director of Mines & Geology concerned shall identify the potential sand
bearing areas on regular basis and place proposals before District Level Sand Committee.

(iii) The Chairman, District Level Sand Committee shall order for joint inspection of identified
sand bearing areas and obtain reports from the following:

(a) The Ground Water Department shall issue the feasibility report under Water,
Land and Tree Rules, 2004 or any suitable subsequent rules/amendments to be
issued by Government from time to time with geo-coordinates of the specified sand
bearing areas, with specific recommendations on the mode of sand extraction.

(b) The Executive Engineer/River Conservator shall issue clearance for the ramps
with Geo-coordinates.

(c) The Revenue Department shall demarcate the specified sand bearing area and
furnish plan on village map.

(d) The Assistant Director of Mines & Geology shall arrive at the quantity of sand
basing on the Ground Water Dept., feasibility report.

(iv) (a) The Collector & Chairman, District Level Sand Committee shall finalize the
specified sand bearing areas as per sub-rule (iii) and issue in-principle allotment
notice to Telangana State Mineral Development Corporation calling for Approved
Mining Plan, Environmental Clearance and Consent for Operation within (3)
months.

On application filed by the Telangana State Mineral Development Corporation, the

Chairman DLSC may give a (3) months extension for submission of Statutory Clearances.

(b) Telangana State Mineral Development Corporation shall obtain the following statutory
clearances:
(i) Approved mining plan from the Deputy Director of Mines & Geology of the
Region concerned.

(ii) Environmental Clearance (EC) from State Environment Impact

Assessment Authority.

(iii) Consent for Establishment (CFE)/Consent for Operation (CFO) from

Telangana State Pollution Control Board.

(c) On submission of Statutory Clearances, the Chairman, District Level Sand

Committee shall allot the specified sand bearing area to Telangana State Mineral
Development Corporation Limited for extraction of sand.

(d) M/s Telangana State Mineral Development Corporation Limited shall execute a
lease deed in Form-S1 with Assistant Director of Mines and Geology concerned
within (15) days from the date of allotment order.
On application filed by M/s Telangana State Mineral Development Corporation
Limited, the Chairman, District Level Sand Committee may condone the delay and extend
the time for a period of (15) days for execution of lease deed.

207
(v) Extraction of sand from specified sand bearing areas:

Telangana State Mineral Development Corporation after

execution of lease deed shall:
(a) Extract sand by engaging a raising contractor from the specified sand bearing area to an
approved stock yard. The raising contractor will be selected under strict competitive
bidding process.

(b) The sand extraction shall be under electronic surveillance and electronic
documentation linked to a central documentation monitoring facility to be developed by
Telangana State Mineral Development Corporation.

(c) The extraction of sand shall be manual or mechanized as per the approved mining plan
and Environment Clearance.

(d) The extracted sand shall be moved to stock yards and weighed or by volumetric analysis
before unloading at the stockyard.

(e) The purchaser of the sand shall pay the sale price to Telangana State Mineral
Development Corporation and obtain transit pass
/way bill

(f) Loading of sand from the stockyard shall be as per the approved capacity of the vehicle
through weighment.

(g) The transit pass shall have the security seal of Telangana State Mineral Development
Corporation stamp with date, time and indicate the destination/route for tracking by way
of GPS facility to be developed.
(vi) Telangana State Mineral Development Corporation shall dispose sand from the stockyard
as per the sale price fixed by the Government from time to time.

(vii) The Member-Convenor shall convene the District Level Sand Committee (DLSC)
meetings frequently to ensure sand availability in the District.

(viii) The period of allotment for extraction shall be for five (5) years from the date of
agreement subject to:

(a) Assessment of annual replenishment of sand to sustain the extraction.

(b) Feasibility report by Ground Water, Irrigation Dept., with Approved Mining Plan
and CFO from TSPCB every year.

(c) The period of sand extraction from the allotted area shall be as per the local
conditions, reflected in the Approved Mining Plan and CFO.

(d) During the subsistence of allotment, the DLSC shall review the status before (30)
days from the date of expiry of first year/subsequent year period or exhaustion of
estimated quantity and order for joint inspection to explore continuation of extraction after
fulfilment of Rule 4(viii)(b).

(e) If the specified sand bearing area is feasible for sand extraction, the Chairman-
DLSC shall call for Mining Plan, CFO and approve for continuation of extraction.

208
 (f) If the specified sand bearing area is not feasible for sand extraction, the Chairman-
DLSC shall order for stoppage of sand extraction for a specified period and Telangana
State Mineral Development Corporation shall safeguard the area.

(g) Due to any reason, the allottee can surrender the area allotted by making an
application to the Chairman, DLSC through the Member-Convenor.

(2) Constitution of State Level Committee (SLC):

The State Level Committee shall consists of the following Officers:

(a) Chief Secretary : Chairman
(b) Director General of Police : Member
(c) Spl. C.S. & CIP, Ind.&Com.Dept. : Member
(d) Prl. Secy. Revenue Dept. : Member
(e) Prl. Secy., Rural Development : Member
(f) Prl. Secy. I&CAD Dept. : Member
(g) VC&MD, TSMDC : Member
(h) Commissioner, Rural Development : Member
(i) Commissioner, Transport Dept. : Member
(j) Member-Secretary, TSPCB : Member
(k) Director, Ground Water Dept. : Member
(l) Engineer-in-Chief, Irrigation Dept. : Member
(m) Director of Mines & Geology. : Member-
Secretary
The State Level Committee shall meet periodically to take up review of the performance, the
matters referred by District Level Sand Committee for review of any statutory provisions and
issue necessary guidelines for proper implementation of the Rules.

5. Responsibility of the M/s Telangana State Mineral Development Corporation Ltd:

(1) Telangana State Mineral Development Corporation shall:

(a) Enter into an agreement with Assistant Director of Mines and Geology by furnishing
bank guarantee for an amount equivalent to 10% of the total seigniorage fee on assessed
quantity as security deposit.

(b) Extract sand as per the Approved Mining Plan and other conditions laid in the
clearances issued under the River Conservancy Act, 1884, the Water Land & Trees Act,
2002 and the Environment Protection Act, 1986 and Air & Water Pollution Prevention
Act, 1974 and amendments thereon or any suitable subsequent Act/rules/amendments to be
issued by Government from time to time.

(c) No transfer or subletting of the allotted sand bearing area.

(d) Extract and dispatch sand from the allotted sand bearing area to approved
stockyard alongwith the way bill in Form-S2 issued by the Asst. Director of Mines and
Geology concerned after paying the Seigniorage fee and other taxes as per the prevailing
scheduled rate or revised from time to time.

(e) (i) Establish a stockyard near to the lifting point having good road facilities and
also additional stockyards near urban habitations, especially the Municipal
Corporations.

209
 (ii) Shall obtain Mineral Dealer License for the stockyard under Mineral Dealer
Rules, 2000 from the competent authority. The validity of Mineral Dealer License
shall coterminous with the period of agreement.

(iii) If any sand stocks leftover after the period of agreement, on representation by
the allottee, the validity of Mineral Dealer License may be extended by the
Licensing Authority after report by the Asst. Director of Mines & Geology.

(iv) The period of extension shall be based on verification of stocks and the
previous daily dispatches.

(f) Sand from stockyard shall be dispatched by Telangana State Mineral Development
Corporation with transit pass (Form-E) issued by Assistant Director of Mines and
Geology concerned alongwith the computerized weighment slip.

(g) The dispatch of sand from the stockyard shall be under electronic surveillance and
electronic documentation linked to a central documentation monitoring facility.

(h) Use of machinery is permitted for making ramps, pathways and maintenance.

(i) Extraction of sand from sand bearing area shall be by manual or mechanized means
subject to permission from the District WALTA Authority on a condition that there is no
impact on ground water table.

(j) (i) Maintain daily production and dispatch register at the allotted sand
bearing area.

(ii) Maintain daily stock and dispatch register at the mineral Dealer stockyard.

(iii) Shall submit returns under A.P. Minor Mineral Concession Rules, 1966 and
A.P. Mineral Dealer Rules, 2000 or any suitable subsequent rules/amendments
to be issued by Government from time to time to the Competent Authorities.

(k) Be penalized for any extraction of sand beyond the specified area; beyond the
specified thickness and for any other violations.
Penalty of Rs.1,00,000/- or Rs.500/- per Cu.Mt. of sand quarried beyond the
specified limits or in excess of thickness stipulated, whichever is higher.

(2) In the event of contravention of any of these rules and the conditions specified in
Agreement of allotment during extraction of sand, the allotting authority shall after giving
an opportunity, impose an appropriate penalty.

6. Regulation of Sand extraction in III and above order streams/Rivers:

(1) The transportation of sand extracted from III and above order Streams/Rivers shall be
utilized anywhere within the State.

(2) The District Collector shall put in place a proper administrative mechanism for
enforcement of extraction and transportation of sand comprising of:

(a) Joint Collector/Addl. Jt. Collector.

(b) Project Officer, ITDA concerned (in respect of Scheduled areas).

(c) Deputy Transport Commissioner/RTO

210
 (d) Asst. Director of Mines & Geology.
(e) Executive Engineer, Irrigation/River Conservator.
(f) Any other nominee(s) by the District Collector.”

7. De-casting sand from Pattalands:

In case of the sand cast in pattalands, the pattadar shall be allowed to de-cast sand to make
the land fit for agriculture.
To eliminate vested interests, no Agent/GPA/Lease holders other than the pattadar shall be
involved in de-casting process.

(1) De-casting in pattalands abutting the river course:

(a) The pattadar shall apply to the Asst. Director of Mines & Geology concerned
alongwith copy of pattadar pass book and Title deed book and location of the
land on village map.

(b) Asst. Director of Mines & Geology concerned shall take up joint inspection of the
pattaland with the following:
(i) Tahsildar shall identify the pattaland, possessor/ occupier and furnish
attested sketch demarcating the area. The boundaries will then be fixed on
ground.

(ii) Mandal Agriculture Officer shall certify that without de-casting the
pattaland is not fit for agriculture.

(iii) The Ground Water Dept. shall record the geo- coordinates of the pattaland
as per boundaries fixed by the Tahsildar, assess the thickness, quantify the
sand to be de-casted and give specific recommendation on the mode of de-
casting i.e. manual or mechanized.

(iv) Asst. Director of Mines & Geology shall certify the suitability of sand for
construction.

(v) Executive Engineer, Irrigation Dept., concerned shall report on the location
of patta land with reference to river course/bed.

(2) After receipt of joint inspection report, the Asst. Director of Mines & Geology shall submit
the proposals duly stipulating the period of de-casting to the District Collector.

(3) District Collector after scrutiny shall submit proposal to the Govt.

(4) After receipt of orders from the Govt. the Asst. Director of Mines & Geology concerned
shall collect the seigniorage fee for the entire assessed sand quantity in advance, security
deposit in the form of Bank Guarantee in favour of Asst. Director of Mines & Geology
equivalent to seigniorage fee on the assessed sand quantity and enter into an agreement in
Form-S5 before issue of dispatch permits in Form-S3.

If Ad valorem rate of seigniorage fee is imposed, the Telangana State Mineral

Development Corporation rate will be the bench mark for payment of seigniorage fee for
de-casting sand from pattalands.

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(5) Responsibilities of the pattadar:
(a) Shall extract sand from the pattaland by manual/mechanized means as
recommended by Ground Water Department and transport to the stockyard by
tractors capacity not more than 3 cu. mt. alongwith transit form issued by the
Asst. Director of Mines & Geology.

(b) Shall establish a stockyard by obtaining registration under MDR, 2000 or any
suitable subsequent rules/amendments to be issued by Government from time to
time from the Competent Authority at a location having proper road
connectivity.
(c) Shall dispatch sand from the stockyard to the consumers with Transit Pass in
Form-E issued by Asst. Director of Mines & Geology concerned under MDR,
2000 or any suitable subsequent rules/amendments to be issued by Government
from time to time.

(d) Shall dispose sand from the stockyard as per the sale price fixed by the
Government from time to time.

(e) Loading of sand from the stockyard shall be as per the approved capacity of the
vehicle with transit pass duly indicating the destination, date and time.

(f) Any contravention by the pattadar during the de-casting, the Chairman, DLSC
may order for collection of:

(i) Rs.1,00,000/- or Rs.500/- per cu.mt. whichever is higher shall be collected

as penalty on de-casting of sand beyond the specified limits or in excess of
permitted depth.
(ii) Repeated violations will result in cancellation of permission and forfeiture
of security deposit.

(iii) Penalty of Rs.10,000/- per ton on vehicles carrying more than the permitted
capacity from the stockyard

(6) To prevent indiscriminate removal of sand from pattalands abutting the Riverbed, more
rigorous vigilance and inspections shall be taken up.

(7) The District Level Sand Committee shall issue operational guidelines for de-casting sand
from pattalands abutting river bed.

(8) The pattalands located in the midst of the river course/bed:

In case of pattalands located in the midst of the river bed/course, the pattadar shall
enter into an agreement for removal of sand by Telangana State Mineral Development
Corporation Ltd.
The Chairman, District Level Sand Committee shall allot the pattalands located in the
midst of the river course/bed to Telangana State Mineral Development Corporation
Limited as per Rule 2(i) readwith Rule 4 (iv) (c).

8. Applicability of these Rules on sand sourced in the process of de-silting:

The Superintending Engineer, Irrigation & Command Area Development Department
concerned shall:

212
(a) Obtain the administrative approval from the Competent Authority for de-siltation of
Reservoirs and Tanks as defined by the Irrigation & Command Area Development
Department, to enhance the storage capacity of the reservoirs and augment Ground Water
recharge in Command Areas.

(b) With approval of District Level Sand Committee shall notify the reservoirs proposed for
de-siltation in March every year.

(c) All the notified reservoirs and tanks shall be handed over to the Telangana State Mineral
Development Corporation Ltd. for de-siltation.

(i) The disposal of sand out of de-siltation of Reservoirs and Tanks shall be in
accordance with the procedures under these TSSM Rules, 2015 or any
amendments issued from time to time.

(ii) Sand de-silted shall be dispatched to the stock yard registered under A.P. Mineral
Dealer Rules, 2000 by competent authority with Form-S4 issued by the Asst.
Director of Mines & Geology concerned.

(iii) Sand shall be disposed from the stockyard as per the sale price fixed by the Govt.
from time to time with Transit Passes in Form-E issued by the Asst. Director of
Mines & Geology concerned.
(d) Sand sourced out of de-silting operations shall be utilized from the stock yards for various
civil works with preference to Govt. Depts.,
(e) The orders issued earlier for continuation of 2nd or subsequent year if any, after payment
of required fees or upset price to Government allotted to any agency on nomination basis
or by other means shall be seized after completion of its allotted/to be allotted period.

9. Crushed Stone Sand as alternative to natural sand:

Alternate to River sand in the form of Crushed Stone Sand (Manufactured Sand) shall be
encouraged from the conservation point of view to River bed/in-Stream sand quarrying operations
at affordable cost be made available to meet the requirement of bulk consumers by following:
(i) By according industry status as long as the unit manufactures 100% sand for availment of
VAT and power subsidy prospectively.

(ii) Regular incentives will be extended for new units.

(iii) Preference in quarry lease allotment
(iv) Existing Stone Crushers will be accorded ancillary status subject to crushed stone sand
certified by ISO/NAC/NCCBM
(v) The Government Departments shall be mandated to use at least 50% of manufactured sand
in Government constructions.

10. Fixation/Revision of rates of sand and seigniorage fee:

(vi) The Government shall fix the rates and revise the rates of seigniorage fee as per the
situation/demand warrants.

If ad-valorem rate of seigniorage fee is imposed, Telangana State Mineral Development

Corporation rate will be the Bench mark for collection of seigniorage charges on sand from de-
casting as well as de- silting.

(vii) The price of sale of sand per Cu.Mt./Ton shall be determined by the respective
District Level Sand Committee keeping in view of the prevailing cost of production and logistics
therein and submit to the Govt. for approval.

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11. Apportionment of Seigniorage Fee to Zilla Parishad General Funds:

100% Seigniorage Fee shall be remitted to the General Funds under the Head of Account of
Zilla Parishad concerned. The same shall be apportioned in the ratio of 25:50:25 among Zilla
Parishad, Mandal Parishad and Gram Panchayat respectively.

12. Ban on sand transportation across border:

No transportation of sand from the State shall be made across the border to other States.
13.Offences:

Any sand lorry found without valid waybill issued by Telangana State Mineral Development
Corporation or by the pattadar (de-casting) will be deemed illegal and the vehicle shall be seized.
(1) Any machinery and vehicles used for extraction and transportation of sand in
contravention to these rules shall be seized.

(2) The following officers in the State are authorized under these rules to seize a machinery
or vehicle involved in illegal sand extraction and transportation.
a) Sub-Collector/Revenue Divisional Officer (concerned).
b) Tahsildar (concerned) Mandal.
c) Sub-Divisional Police Officer (concerned).
d) Station House Officer (concerned).
e) District/Divisional Panchayat Officer
f) Asst. Director of Mines & Geology (concerned).
g) Any other officer nominated by the Dist. Collector
(concerned).

(3) An officer authorized to seize any machinery/vehicle as per sub- rule (1) shall keep
machinery/vehicle with Station House Officer concerned or Tahsildar concerned for safe
custody and shall submit a report of such seizure to the Competent Court of Law.

(4) An authorized officer who seizes any machinery/vehicle shall order confiscation of the
machinery/vehicle so seized.

(5) No order of confiscation of any machinery/vehicle shall be made under sub-rule (4)
unless the person from whom the machinery/vehicle is seized is given:-

(a) A notice in writing informing the person of the grounds on which it is proposed to
confiscate such property.

(b) An opportunity of making a representation in writing within such time as may be

specified in the notice against the grounds for confiscation; and
(c) A reasonable opportunity of being heard in the matter.
(6) Officers seized the vehicle shall issue order of confiscation of machinery/vehicle. The
confiscated machinery or vehicle shall be disposed in public auction.

14. Disposal of seized sand:

The Tahsildar (or) the officers nominated by Tahsildar at Mandal Level; Sub-
Collector/Revenue Divisional Officer (or) the officers nominated by the Sub-
Collector/Revenue Divisional Officer at Divisional Level; the Joint Collector/the District

214
 Collector (or) the Officers nominated by the Joint Collector/the District Collector at
District Level shall seize illegal sand stocks. Such seized sand shall be kept under safe
custody of concerned Tahsildar and the same shall be disposed through Telangana State
Mineral Development Corporation.

15. Appeal and Revision:

(viii) In case of I and II order streams:
(a) Any person aggrieved by an order passed by the Mandal Authority/ may prefer
the appeal before the Joint Collector within fifteen (15) days from the date of
receipt of such order.

(b) Any person aggrieved by an order of the Joint Collector may prefer revision
before the District Collector within fifteen (15) days from the date of receipt of
such order.

(ix) In case of III and above order streams/rivers.

Any order passed by the Chairman, DLSC, Deputy Director of Mines & Geology
or Asst. Director of Mines & Geology, the allottee may prefer an appeal to the Govt.
within (30) days from the date of receipt of such order.

16. Restriction on issue of licence for stocking /storing /trading of sand :

No other person or agency other than Telangana State Mineral Development

Corporation and a pattadar having permission for de-casting of sand from his /her patta land from
the competent authority for the specified area mentioned therein shall be issued licence for
stocking /storing /processing /trading of sand including manufactured sand under AP Mineral
Dealer Rules, 2000 or under any suitable subsequent rules
/amendments to be issued by the Government from time to time.

17. Powers to Issue Orders/Clarifications/Guidelines:

The Government shall be the Authority to issue clarifications; guidelines or relaxation orders
from time to time, in implementation of these rules.
18. Saving Clause:

(1) Leases which have not yet started shall be continued by the terms and conditions of the
grant until expiry of lease except in those cases wherein the Government in the public
interest decides otherwise.
(2) Leases under operation shall be continued by the terms and conditions of the grant until
expiry of lease except in those cases wherein the Government in the public interest decides
otherwise.

19. Applicability of General Provisions:

The General provisions of Minor Mineral Concession Rules, 1966 or any suitable
subsequent rules/amendments to be issued by Government or the orders, guidelines,
clarifications issued by Government in this regard from time to time shall apply for cases
which are not explicitly mentioned herein.

[BY ORDER AND IN THE NAME OF THE GOVERNOR OF TELANGANA]

K. PRADEEP CHANDRA
SPECIAL CHIEF SECRETARY TO GOVERNMENT AND
COMMISSIONER FOR INDUSTRIAL PROMOTION

215
To
The Commissioner of Printing, Stationary & Stores Purchase (Ptg. Wing) Hyderabad. (He is
requested to publish the above Notification in the Extra- Ordinary issue of Telangana
Gazette, and arrange to send 2500 copies of the same to Government in Industries &
Commerce (M.I) Department)

The Director of Translation, Telangana, Hyderabad. (He is requested to furnish the Telugu
version of the Notification direct to the Commissioner, Printing, Stationary & Stores
Purchase (Ptg.Wing), Hyderabad)

The Director of Mines and Geology, Telangana State, Hyderabad The Vice
Chairman & Managing Director,
Telangana State Mineral Development Corporation Ltd., Hyderabad.
All the District Collectors/Joint Collectors in the state of Telangana through
Director of Mines and Geology, Hyderabad.
The Irrigation & CAD Department.
The Panchayat Raj & Rural Development Department The
Revenue Department.
The Commissioner of Panchayat Raj, Hyderabad All the
Departments of Telangana Secretariat.
Copy to :
P.S. to Principle Secretary to the Hon’ble Chief Minister.
P.S to Hon’ble Minister for Mines and Geology.
P.S. to Hon’ble Minister for Panchayat Raj & Information Technology.
P.S. to Hon’ble Minister for Irrigation.
P.S. to Chief Secretary to Government.
P.S. to Special Chief Secretary to Government & CIP, Ind & Com Dept.
to Secretary to Government, Ind & Com Dept.,
The Joint Directors/Deputy Directors/Assistant Directors of Mines and Geology Deptt., through
the Director of Mines & Geology, Hyderabad.
The Law Department.
The General Administration (Cabinet) Department. Sf/Sc.
(C.No.9060/M.I(1)/2014)

//FORWARDED :: BY ORDER//

SECTION OFFICER

216
 FORM – S1

Agreement of Allotment of Specified Sand Bearing Area. [See Rule

4(iv)(d)]

This agreement entered into on this _ day of , 20

between Asst. Director of Mines & Geology District on behalf of

Government of Telangana State, referred to as the Allotter, which expression shall unless
repugnant to the subject or context mean and include its successors, assignees and representatives
etc., on one part.

AND

M/s _, Rep. by located at

(hereinafter referred to as the Allottee) which expression shall include

its successors in interest, legal representatives etc. on other part.

Whereas, the Joint Collector vide order No. dated allotted the
specified sand bearing area for extraction and transportation of sand to the stockyard situated
between the following geo-coordinates:

Geo-Coordinates Qty. of sand

Sl. Reference Point Extent to be
No. Longitude Latitude (in Ha) extracted (in
Cu.Mt)
Specified sand bearing area

Ramp particulars

This contract is subject to the extent, terms and conditions of order, Approved Mining Plan,
A.P. WALT Rules, 2004, Environmental Clearance and Telangana State Sand Mining Rules, 2015
or any suitable Rules/Amendments to be issued by Govt. from time to time.

NOW IT IS MUTUALLY AGREED AND DECLARED BY AND BETWEEN PARTIES

HERETO AS FOLLOWS:

1. SCOPE OF THE WORK:

(i) The Allottee shall extract sand from the specified sand bearing
area situated at _ Village, _ Mandal, District.
(ii) Transport the extracted sand to the specified stockyard by tractors having
capacity not more than 3 Cu.Mt. and
(iii) Dispose sand from the specified stockyard under Electronic
Surveillance (CCTV).

ADM&G ALLOTTEE

TSMDC LTD.

217
 2. PERIOD OF THE AGREEMENT:

(i) The agreement shall be inforce with effect from _ to .

(ii) The period of agreement may be extended subject to annual

replenishment of sand for a maximum period of five years.

(iii) The agreement is not transferable.

3. QUANTITY OF SAND TO BE EXTRACTED; The Allottee shall:

(i) Extract sand as per the quantity indicated from the specified sand
bearing area as estimated, during the period of agreement in consonance
with Approved Mining Plan/Environment Clearance/ Consent for
Operation.

(ii) While extracting sand shall confine to the thickness specified in the
Approved Mining Plan and to the boundaries
fixed.
(iii) Extract indicated quantity of sand during the period of agreement and
transport to specified stockyard duly paying Seigniorage Fee in advance
as per the prevailing rates or revised rates from time to time.

(iv) Obtain Mineral Dealer License as per A.P. Mineral Dealer Rules, 2000 or
any suitable Rules/Amendments to be issued by Govt. from time to time
for stocking of sand from the specified sand bearing area.

(v) Dispatch sand from the specified stockyard after obtaining Transit Passes
in Form-E from the competent authority.

(vi) Maintain records of dispatch of sand from the specified sand bearing area
to the specified stockyard and shall file monthly returns on the quantity
of sand extracted to the Asst. Director of Mines & Geology & Deputy
Director of Mines & Geology concerned.

(vii) Maintain records of dispatch of sand from the specified stockyard and file
returns to the competent authority as per A.P. Mineral Dealer Rules, 2000
or any suitable Rules/Amendments to be issued by Govt. from time to
time.

4. PAYMENT OF SEIGNIORAGE FEE:

The Allottee shall pay Seigniorage Fee in advance before dispatch of sand from the
specified sand bearing area to the authorized stockyard as per the prevailing scheduled rates
or revised from time to time in the Zilla Parishad General Funds and furnish challan to the
Asst. Director of Mines & Geology for obtaining waybills.

5. CONDITIONS: The Allottee shall:

(1) Abide by the conditions and the rules made under River Conservancy Act, 1884,
Andhra Pradesh Water Land & Trees Act 2002 or any suitable
Rules/Amendments to be issued by Govt. from time to time and Environment
Protection Act 1986 and subsequent amendments issued by the State and
Central Governments from time to time.

ADM&G ALLOTTEE

TSMDC LTD.
218
 (2) Pay the Seigniorage fee and obtain way bills in Form S-2 from the Asst. Director
of Mines & Geology concerned and dispatch sand from the specified area to
specified stock yard.

(3) Maintain daily production and dispatch register and statutory returns/clearances
prescribed under various statutes at the specified area.

(4) Extract sand from the specified sand bearing area in a systematic manner as per
approved mining plan and Environment Clearance issued by Ministry of
Environment and Forests.

(5) Not use Tractors more than 3 Cu. Mt. capacity for transportation of sand from
specified sand bearing area to stock yard.

(6) Use the ramp and pathways permitted by the Executive Engineer/ River
Conservator.

(7) Not allow tractors carrying sand to ply over the flood banks except at approved
ramp points.

(8) Use the paths authorized by the Tahsildar concerned to approach the specified sand
bearing area.

(9) Transportation of sand from specified sand bearing area to the stockyard shall be
through designated route only.

(10) Not extract sand more than the permitted quantity and beyond the specified
thickness. Sand extracted beyond the specified boundaries or in excess of
permitted thickness shall be treated as unauthorized sand extraction and liable for
penalization.

(11) Extraction of sand from the specified sand bearing area shall be by manual means
and no machinery is permitted except in specific sand bearing areas where there is
no impact on Ground Water table and with the prior approval of District
Collector/District WALTA Authority.

(12) Erect and maintain at his own expense, boundary pillars at each corner or angle in
the line of boundary of the Specified Sand Bearing Area allotted.

(13) Install at their expense:

(i) CCTVs at both the specified sand bearing area as well as stockyard.

(ii) Computerized weigh bridge at stockyard.

6. Any other specific condition deemed fit in the opinion of the confirmation authority on a
case–to–case basis as per local conditions (to be mentioned).

ADM&G ALLOTTEE

TSMDC LTD.

219
 Government of Telangana
Form –S2
Sand Way Bill Form specified sand bearing area
[See Rule 5(1) (d)]

Way Bill No. District Code.

Book No.
1. Name & Address of the Allottee :

2 Description of specified sand :

bearing area

a) Name of the area

b) Village
c) Mandal

3. Date and time of issue :

4. Quantity under transportation : 3.00 Cu. Mt.

5 Vehicle No. :

6 Location of specified Stockyard :

a) Survey No.
b) Village
c) Mandal

7 Date and time of receipt at :

Stockyard

Signature of the Allottee. Signature

Authorized representative of the Issuing Authority

Note:

1. Overwriting in any form in the way bills makes it invalid.

2. The driver shall carry the duplicate stamped copy of the way bill and handover it
to the authorized person of the allottee at the designated stockyard.
3. The original Transit Form shall be surrendered to the issuing authority concerned
within 15 days from the date of dispatch and the duplicate form shall be retained
by the allottee to obtain transit passes.
4. The tractor driver shall produce the way bill to any authorized authority for
checking purpose.

220
 Government of Telangana
Form –S3
Sand Way Bill Form for Pattalands [See
Rule 7(4)]

Way Bill No. District Code

Book No. _

1. Name & Address of the Pattadar :

2. Order No. & Date of permission

issued by ADM&G. :

3. Details of sand bearing area :

a) Sy.No. :
b) Village
c) Mandal :
d) Extent :

4. Location of the Stockyard :

a) Sy.No.
b) Village
c) Mandal

5. Date & Time of issue :

6. Vehicle No. :

7. Quantity : 3.00 cum

8. VAT/TIN No. :

Signature of the Pattadar

Signature of the
Issuing Authority

Conditions :

1. Overwriting in any form in the way bills makes it invalid.

2. The driver shall carry the duplicate stamped copy of the way bill and hand over it at
stockyard.
3. The original Transit Form shall be surrendered by the pattadar to the issuing authority.
4. The tractor driver shall produce the way bill to any authorized authority for checking
purpose.

221
 Government of Telangana
Form –S4
Way Bill Form for De-silted Sand
(See Rule 8(c)(ii)

1. Name of the Reservoir/Tank :

2. Order No. & Date of permission of Engg-in- : Chief/Chief Engg, I&CAD Dept.

3. Details of de-silting area :

a) Village
b) Mandal
c) District

4. Date & Time of issue :

5. Vehicle No. :

6. Quantity :

7. Location of the stockyard :

a) Sy.No.
b) Village.
c) Mandal.
d) District

Signature of the Allottee/ Signature and Seal of the

Authorized representative Issuing Authority

Conditions:

1. Overwriting in any form in the way bills makes it invalid.

2. The driver shall carry the duplicate stamped copy of the way bill and handover it at
stockyard.

3. The original Transit Form shall be hold with the Issuing Authority.

222
 Form-S5
Agreement for De-casting Sand from the Pattaland. [See
Rule 7(4)]

This agreement entered into on this _____ day of _________ , 20 ________ between
Asst. Director of Mines & Geology ___________ District on behalf of Government of
Telangana State, which expression shall unless repugnant to the subject or context mean and
include its successors, assignees and representatives etc., on one part.

AND

Sri/Smt/M/s _____________ , Rep. by ____________ located at _______ ( here in after

referred to as pattadar) which expression shall include its successors in interest on other part.

Whereas, the collector vide order No. ________ dated ________ accorded permission
for de-casting sand from pattaland and transportation to the stockyard situated between the
following geo-coordinates:

Pattaland permitted for de-casting sand

Geo-Coordinates Qty. of sand
Sl. Reference Point Extent to be
No. Longitude Latitude (in Ha) de-casted
(in Cu.Mt)

This contract is subject to the extent, terms and conditions of order, Telangana State
Sand Mining Rules, 2015 or any suitable Rules/Amendments to be issued by Govt. from time to
time.

NOW IT IS MUTUALLY AGREED AND DECLARED BY AND BETWEEN PARTIES

HERETO AS FOLLOWS:

1. SCOPE OF THE WORK:

(i) The pattadar shall de-cast sand from the specified pattaland
situated in Survey No. _, Village, _ Mandal,
District.
(ii) Transport the de-casted sand to the specified stockyard by tractors having
capacity not more than 3 Cu.Mt. and
(iii) Dispose sand from the specified stockyard.

2. PERIOD OF THE AGREEMENT:

(i) The agreement shall be inforce with effect from _ to .

(ii) The agreement is not transferable.

ADM&G PATTADAR

223
 3. QUANTITY OF SAND TO BE DE-CASTED; The Pattadar shall:

(i) De-cast sand as per the quantity indicated in the order of confirmation
from the specified pattaland as estimated by the Ground Water
Department during joint inspection.

(ii) While de-casting of sand shall confine to the thickness specified by the
Ground Water Department from the pattaland having the boundaries fixed.

(iii) Pay Security Deposit in the form of Bank Guarantee in favour of the Asst.
Director of Mines & Geology concerned equivalent to the Seigniorage
Fee on the assessed sand quantity for de-casting as per the prevailing rates
or revised from time to time.

(iv) Transport the de-casted quantity of sand during the period of agreement to
the specified stockyard after payment of Seigniorage Fee in advance in
lump sum as per the prevailing rates or revised from time to time.

(v) Obtain Mineral Dealer License as per A.P. Mineral Dealer Rules, 2000 or
any suitable Rules/Amendments to be issued by Govt. from time to time
for stocking of sand from the specified pattaland.

(vi) Dispatch de-casted sand from the specified stockyard after obtaining
Transit Passes in Form-E from the competent authority.

(vii) Maintain records of dispatch of de-casted sand from the specified

pattaland to the specified stockyard and shall file monthly returns on the
quantity of sand de-casted to the Asst. Director of Mines & Geology &
Deputy Director of Mines & Geology concerned.

(viii) Maintain records of dispatched de-casted sand from the specified

stockyard and file returns to the competent authority as per A.P. Mineral
Dealer Rules, 2000 or any suitable Rules/Amendments to be issued by
Govt. from time to time.

4. PAYMENT OF SEIGNIORAGE FEE:

The Pattadar shall pay Seigniorage Fee in full in advance for the total quantity of sand
to be de-casted before de-casting sand from the specified pattaland to the authorized
stockyard as per the prevailing scheduled rates or revised from time to time in the Zilla
Parishad General Funds and furnish challan to the Asst. Director of Mines & Geology for
obtaining waybills.

5. CONDITIONS: The Pattadar shall:

1) Abide by the conditions and the rules made under River Conservancy Act,
1884, Andhra Pradesh Water Land & Trees Act 2002 or any suitable
Rules/Amendments to be issued by Govt. from time to time and Environment
Protection Act 1986 and subsequent amendments issued by the State and
Central Governments from time to time.

ADM&G PATTADAR

224
 2) Obtain way bills in Form S-2 from the Asst. Director of Mines & Geology
concerned and dispatch de-casted sand from the specified pattaland to
specified stock yard.

3) Maintain daily production and dispatch register & statutory returns/clearances

prescribed under various statutes at the specified area.

4) De-cast sand from the specified pattaland in a systematic manner as per

the guidelines issued by the District Collector from time to time.

5) Not use Tractors more than 3 Cu. Mt. capacity for transportation of sand de-
casted from specified pattaland to stock yard.

6) Not allow tractors carrying sand to ply over the flood banks.

7) Use the paths authorized by the Tahsildar concerned to approach the specified
pattaland.

8) Transportation of de-casted sand from specified pattaland to the stockyard shall

be through designated route only.

9) Not to de-cast sand more than the permitted quantity and beyond the specified
thickness. Sand de-casted beyond the specified boundaries or in excess of
permitted thickness shall be treated as unauthorized de-casting and liable for
penalization.

10) De-casting of sand from the specified pattaland shall be by manual means
and no machinery is permitted except in specific pattalands where there is no
impact on Ground Water table and with the prior approval of District
Collector/District WALTA Authority.

11) Erect and maintain at his own expense, boundary pillars at each corner or angle
in the line of boundary of the Specified pattaland for de-casting sand.

6. Any other specific condition deemed fit in the opinion of the confirmation authority on
a case–to–case basis as per local conditions (to be mentioned).

ADM&G PATTADAR

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