2011_12_Manual on Quality Assuarance and Quality Control(Civil Works and HM Works).pdf

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Himachal Pradesh

Power Corporation Limited

Manual on

Quality Assurance & Quality Control

(Civil & HM Works)



Quality Assurance and Quality Control Manual (Civil & HM works)(1 st Edition)

Government of Himachal Pradesh has allotted a number of Hydro Electric Projects t

HPPCL for its speedy execution in a clean and healthy environment. HPPCL is planning to

harness 3000 MW by March 2017 and 5000 MW by 2022 confirming to all quality

norms/standards in practice.

Quality in construction implies fulfillment of technical, financial and societal need

which the HEPs are intended to satisfy during construction and operational phase. Fo

setting and defining the level of desired quality and achieving it in actual construction, an

attempt has been made to prepare/finalize a manual on Quality Assurance & Qualit

Control (Civil & HM works) to be implemented in all HEPs under HPPCL. The subsequen

editions incorporating the changes arising due to advancement in Construction Technologyand Quality Management will be released from time to time.

The following HPPCL officers/Consultant ( s ) were associated: -

1.

Er. B. S. Negi, Director (Civil), HPPCL

2. Er. P. K. Kohli, General Manager (Designs), HPPCL.

3.

Er. Sanjeev Arya, DGM (CM), HPPCL.

Consultant: -

1.

Er. Vijay Chopra, Ex. E. D., SJVVNL cum HPPCL Consultant.

The 1st edition of this Manual on Quality Assurance and Quality Control (Civil &

HM works) is being released on 12th May, 2011.



Himachal Pradesh Power Corporation Limited


Part-I (Civil Works)

INDEX

1. CHAPTER – I Page - 1

QUALITY ASSURANCE, QUALITY CONTROL & INSPECTION Page -1

1.1 Introduction Page -1

1.1.1 Orientation and Training of Construction Supervision &

Quality Control Staff

Page -3

1.1.2 Laboratory System for Testing of Input and Outputs Page -3

1.1.3 O.K. Card System Page -3

1.2 Objectives and Scope of Quality Control Page -4

1.2.1 Objectives Page -4

1.2.2 Roles and Responsibility Matrix Page -4

1.3 Quality Control Manual Page -8

1.4 Configuration of Quality Management System Page -9

1.5 Definitions Page -10

2. CHAPTER-II Page -11

ORGANIZATIONAL SETUP Page -11

2.1 Quality Control Unit Formation Page -11

2.2 Functions of Quality Control Units Page -12

2.3 Training Requirements Page -14

3. CHAPTER-III Page -17

TESTING LABORATORIES & THEIR FUNCTIONS Page -17

3.1 Objectives Page -173.2 Laboratory Quality System Page -17

3.3 Set-up of Laboratories Page -18

3.4 Functions of Central Field Laboratory (Level-1) Page -19

3.5 Functions of Site Laboratories (Level-2) Page -20

3.6 Functions of Field Testing Units Including Mobile Units (Level-3) Page -20

3.7 Improved Devices for Quality Control Page -23

3.8 Scope of Inspection and Testing Facilities Page -23

4. CHAPTER-IV Page -24

DUTIES & CONTROL OF LABORATORIES Page -24

4.1 Duties of In-Charge of Laboratory Page -24

4.2 Duties of AEs/Assistant Research Officers/Research

Assistants (Laboratory)

Page -24

4.3 Duties of Laboratory Technicians/Junior Research Assistants Page -25

4.4 Duties of Laboratory Attendants. Page -25

4.5 Control of Test Equipment for Inspection, Testing & Measuring Page -25

4.6 Duties of Field Engineers in Relation to Quality of works Page -25





5. CHAPTER-V Page -29

CO-ORDINATIONS Page -29

5.1 General Co-ordination and Linear Responsibility Chart Page -29

5.2 Defects & Deficiencies Page -30

5.3 Test Checks & Sub-Standard Work Page -30

5.4 Difference of Opinion Page -306. CHAPTER - VI Page -32

QUALITY ASSURANCE AND INTERNAL QUALITY AUDIT Page -32

6.1 Quality Assurance Records Page -32

6.2 Quality Audit Page -32

6.3 Internal Quality Audit Page -32

6.3.1 Objectives Page -32

6.3.2 Scope & Functions Page -33

6.3.3 Audit Sampling Page -34

6.4 Internal Quality Audit Group - Desired Standards &

Formation of the group

Page -34

6.5 Program of Quality Audit Page -35

7. CHAPTER - VII Page -38

O.K. CARDS Page -38

7.1 O.K. Card System Page -38

7.2 Filling of O.K. Card Page -38

7.3 Specimen of O.K. Card Page -39

8. CHAPTER - VIII Page -40

TESTS TO BE PERFORMED ON CONSTRUCTION MATERIALS Page -40

8.1 General Page -40

8.2 Tests to be performed Page -408.3 Sampling for Testing of Materials Page -43

9. CHAPTER - IX Page -45

LIST OF EQUIPMENT FOR AND CONCRETE TESTING Page -45

10. CHAPTER - X Page -47

IMPORTANT SPECIFICATIONS AND CONSTRUCTION CONTROL Page -47

10.1 Underground Excavation and Support System Page -47

10.1.1 General Page -47

10.1.2 Care during Underground Construction Page -47

10.1.3 Geological Mapping During Tunnel Excavation Page -50

10.1.4 Geotechnical Monitoring of Underground works and

Instrumentation

Page -50

10.1.5 Shotcreting (Plain/Reinforced) Page -51

10.1.6 The Steel Fibre used in SFRS Page -53

10.1.7 Micro Silica Page -53

10.1.8 Proportion of Admixture

Page -54

10.1.9 General Specifications of Rock Bolts/Anchors Page -56

10.1.10 Support Elements Page -58





10.2 Cement Concrete Work Page -59

10.2.1 Proportioning, Batching & Mixing Page -59

10.2.2 Concrete Mix Design Page -60

10.2.3 Water Cement Ratio (W/C) Page -62

10.2.4 Durability of Concrete Page -62

10.2.5 Workability of Concrete Page -63

10.2.6 Transporting of Concrete Page -63

10.2.7 Placing & Compacting of Concrete Page -64

10.2.8 Curing of Concrete Page -64

10.2.9 Sampling & Testing for Compressive Strength of

Designed Mix Concrete

Page -64

10.2.10 Acceptance Criteria of Compressive Strength Page -65

10.2.11 Additional Tests Page -66

10.2.12 Quality Control of Fresh Concrete Page -66

10.2.13 Construction Joints Page -66

11. CHAPTER XI

Page -67IMPORTANT DO’S AND DON’TS/CHECK LIST FOR UNDERGROUND

WORKS

Page -67

12. CHAPTER XII Page -70

CONTROL ON CONCRETE MATERIALS Page -70

12.1 Cement Page -70

12.1.1 Source of Cement Page -70

12.1.2 Storage and Handling of Cement Page -70

12.2 Aggregates Page -71

12.2.1 Aggregate Characteristics Page -71

12.2.2 Quality of Aggregates Page -71

12.2.3 Control on Gradation of Coarse and Fine Aggregates Page -72

12.2.4 Harmful Materials in Aggregates Page -73

12.2.5 Sampling of Aggregate Page -73

12.2.6 Storage & Handling of Aggregates Page -73

12.3 Water Page -73

12.4 Chemical Admixtures Page -74

12.4.1 Need for use of Admixtures Page -74

12.4.2 Classification of Admixtures & their function in Concrete Page -74

12.4.3 Physical Requirements of Admixtures Page -74

12.4.4 Uniformity Requirements of Admixtures Page -75

12.4.5 Curing Compounds Page -75

13. CHAPTER – XIII Page -77

MONITORING THROUGH CONTROL CHARTS Page -77

13.1 Control Charts for Concrete Strengths Page -77

13.2 Control Charts for Cement Strengths Page -82

13.3 Some useful Relationships Page -84





14. CHAPTER XIV Page -87

COMPILATION OF QUALITY CONTROL DATA & INFORMATION SYSTEM Page -87

14.1 Data, Information & Information system Page -8714.2 Responsibility Chart Page -87

14.3 List of Documents-Check List Page -88

14.4 Standardization of Records Page -89

14.5 Presentation of Information Page -89

14.6 Indexing of Records Page -90

14.7 Value of Information Page -90

14.8 Data Life Cycle Page -91

14.9 Data Processing Page -91

14.10 Movement of Test Reports Page -92





Part-II (Hydro Mechanical Works)

INDEX

CHAPTER-I

INSPECTION OF INCOMING MATERIALS

AND PARTS OF HYDRAULIC STRUCTURES Structural steel & stainless steel

1.0 Scope Page – 1

1.1 References Page – 1

1.2 Freedom From Defects Page – 1

1.3 Chemical Composition Page – 1

1.4 Selection And Preparation Of Test Samples Page – 1

1.5 Round Test Samples Page – 1

1.6 Tensile Test Page – 1

1.6.1 Number Of Tensile Tests Page – 1

1.6.2 Tensile Test Page – 2

1.7 Bend Test Page–

21.7.1 Bend Test Page – 2

1.8 Retest Page – 2

1.9 Tolerances Page – 2

1.9.1 Beams And Columns Page – 2

1.9.2 Camber and sweep Page – 3

1.9.3 Weight Page – 3

1.9.4 Rolling Tolerances For Flats Page – 3

1.9.5 Rolling And Cutting Tolerance For Plates Page – 3

1.9.6 Length Page – 4

1.10 Inspection Of Underslung Hoist Page – 4

1.11 Test Certificates Page–

5

1.12 Details Of Testing Page – 5

1.13 Non Destructive Tests Page – 5

1.14 Repair Of Castings Page – 5

1.15 Chemical Composition Page – 6

1.16 Tolerances Page – 6

1.17 Freedom From Defects Page – 6

1.18 Heat Treatment Page – 6

1.19 Mechanical Properties Page – 6

1.20 Inspection Of Boughtout Items Page – 7

1.20.1 Reduction Unit Page – 7

1.20.2 Wire Ropes Is 2266 – 2000 Page – 7

1.20.3 Plummer Blocks Page – 7

1.20.4 Couplings Page – 7

1.20.5 Clutches Page – 7

1.20.6 Bearings Page – 7

1.20.7 Motors Is 325 Page – 8

1.20.8 Brakes Page – 8





1.20.9 PVC Insulated Cables Page – 8

1.20.10 Control Panels Page – 8

1.20.11 References – Is Codes Page – 8

1.20.12 Quality Assurance Plan For Manufacture, Installation And

Commissioning Of Hydraulic Gates And Handling Equipments

Page – 9

1.20.13 List Of Abbreviation Page–

151.20.14 Steel Plates For Penstock Page – 16

1.20.15 Inspection Of Steel Plates Page – 16

CHAPTER-2

WELDING DETAILS For Hydraulic gates manufacture

2.0 Welding Processes Page – 172.1 Specification Page – 17 2.2 Preparation Of Base Material Page – 172.3 Assembly Page – 18

2.4 Welding Processes Page–

182.5 Weld Consumables Page – 182.5.1 Welding Of Carbon Steel To Carbon Steel Page – 182.5.2 Welding Of Carbon Steel To Stainless Steel Page – 182.5.3 Welding Of Stainless Steel To Cast Steel Page – 182.6 Storage Of Electrodes Page – 182.7 Welding Position Page – 192.8 Nature Of Current Page – 192.9 Tack Welds Page – 202.10 Precautions For Quality Welds Page – 202.11 Limitation Of Fillet Weld Page – 202.11.1 Angle Between Fusion Faces In Degrees Page

– 20

2.11.2 Thickness Of Thicker Part Page – 202.12 Joint Locations Of Hydraulic Gates Page – 212.12.1.1 Vertical Lift Gates Page – 212.12.1.2 Joints In Horizontal Girders Where Ever Possible Page – 212.12.1.3 Welding Of Horizontal Girders To End Vertical Or End Box Page – 222.12.1.4 Lifting Arrangement Page – 222.12.1.5 All Other Welds Are Also More Important And Continuous One To

Control The Rust Page – 22

2.12.2 Radial Gates Page – 232.12.2.1 Skin Plate Assembly With Vertical Stiffeners Page – 232.12.2.2 Horizontal Girders Page

– 25

2.12.2.3 Tie Between Trunnion Page – 262.13 Welding Defects : Their Causes And Prevention Page – 272.13.1 Welding Objectives Page – 272.13.2 Typical Defects Which Can Occur In Arc Welds Page – 282.13.2.1 Incomplete Penetrations Page – 282.13.2.2 Lack Of Fusion Page – 28





2.13.2.3 Undercut Page – 292.13.2.4 Overlap Page – 292.13.2.5 Slag Inclusions Page – 302.13.2.6 Porosity Page – 312.13.2.7 Crack Page – 31

2.13.2.7.1 Hot Cracks Page–

322.14 Standard Time For Fillet Welding Page – 332.15 Number Of Standard Electrodes Per Meter Length Of Joints Page – 342.16 Number Of Standard Electrodes Per Meter Length Of Joints Page – 352.17 Comparative Chart For Welding Electrodes Page – 36

CHAPTER-3

QUALITY CONTROL & TESTS OF GATES, PENSTOCK

& ALLIED MECHANICAL WORKS 3.0 Proper Quality Control And Quality Assurance Page-38

3.1 Manufacturing Stage Page-383.1.1 Non-Destructive Testing Shall Be Conducted As Per Indian

Standard Codes

Page-38

3.1.2 Destructive Testing Page-383.2 Test During Installation/Erection Stage Page-393.3 Additional Checks For Radial Gates Page-403.4 General Tools Required For Q.C. Agencies Page-403.5 General Quality Control Tests For Gates And Allied Components Page-413.5.1 Raw Materials And Bought Out Items Page-413.5.1.1 Inspection And Random Testing Of All Raw Materials Such As Page-41

3.6 Tests Required During & After Installation / Erection Page-42

3.7 Tests Required During The Stage Of Manufacture Page-433.7.1 Additional Tests For Radial Gates Page-43

3.7.2 Testing And Commissioning Page-43

3.7.3 Penstock Page-44

3.7.3.1 Shop/Field Inspection Page-443.7.3.2 In-Process Inspection Page-44

3.7.3.3 In-Process Inspection Of Fabrication Page-453.7.3.4 Coating And Lining Inspection Requirements Page-463.7.3.5 Final Shop Inspection Page-46

3.7.3.6 Final Field Inspection Page-473.7.3.7 Damage Page-47

3.7.3.8 Field Weld Inspection Page-473.7.3.9 Field Inspection Of Linings And Coatings Page-473.7.3.10 Bedding And Backfill Page-473.7.3.11 Reports Page-473.7.4 Non-destructive Examination Page-473.7.4.1 General Page-473.7.4.2 Minimum Non-destructive Examination Requirements (ASCE Manual) Page-483.7.4.3 Areas Requiring Special Consideration Page-48





3.7.5 Non-destructive Examination Methods Page-493.7.5.1 Radiographic Examination Page-493.7.5.2 Ultrasonic Examination Page-493.7.5.3 Magnetic Particle Examination Page-493.7.5.4 Liquid Penetrant Examination Page-49

3.7.5.5 Visual Examination Page-503.7.5.6 Field Hydrostatic Testing Page-503.7.5.7 Field Test Pressure Page-503.7.5.8 Hydrostatic Test Inspection Verification Page-51

CHAPTER-4

PAINTING SYSTEM FOR HYDRAULIC GATES & HOISTS 4.0 Introduction Page-524.1 Surface Preparation Page-524.1.1 B Sa 2½ Page-534.1.2 B Sa 3 Page-534.2 Shop Painting Page-544.2.1 Embedded Parts Which Come Into Contact Of Concrete Page-544.2.2 Embedded Parts Which Are Not In Contact With Concrete And Gate

Parts Page-54

4.3 Gates Page-544.3.1 Primer Coat Page-54

4.3.2 Finished Paint Page-544.4 Hoist And Supporting Structure Page-554.4.1 Structural Components Page-554.4.2 Machinery Page-554.4.3 Machined Surfaces Page-554.5 Application Of Paint Page-554.6 Removal Of Old Paint/Rust And Carrying Out Fresh Painting Page-564.7 Removal Of Old Paint For Repainting Page-564.8 Inspection And Testing Of Painting Page-564.8.1 General Page-574.8.2 Inspection Of Surfaces Prior To Painting Page-574.8.2.1 New Work (Note Previously Painted) Page-574.8.2.2 Old Work (Which Requires Repainting) Page-574.8.3 Inspection During Preparation Of Surfaces Page-574.8.4 Inspection Before And During Intermediate Protective Treatments Page-584.8.5 General Inspection Before And During Painting Page-584.9 Spray Painting Defects: Causes And Remedies Page-594.9.1 Defects In Finish Page-594.9.2 Defects In Workmanship Page-60





O. K. Cards

INDEX

Civil Works

Excavation Page – 1

Underground Structures-Concrete Lining Page – 3

Placement of Concrete for Dam/Open Works Page – 5

Placement Report Page – 7

Reinforcement Inspection Checklist Page – 8

Plain and Reinforced Cement Concrete work Page – 9

Compressive Strength of Concrete Page – 11

Rock Bolt Test Result Page–

12 Sieve Analysis for Sand/Fine Aggregate (IS:383) Page – 13

Calibration of Batching Plant Page – 14

Safety Checklist Page – 15

Hydro Mechanical Works

1 & 2 Stage Embedments Page – 16

Authorization Powers Page – 17

DT Gates Page – 18

DT Gates 2nd Stage Page – 19

Erection of Gates Page–

20Gantry Crane Hoist Page – 21

Hydraulic Hoist Piping Page – 22

Legends Page – 23

Receipt & Storage Page – 24

Storage & Receipt Page – 25

Storage & Receipt Page – 26



Himachal Pradesh


Part-I

Civil Works



Quality Assurance & Quality Control (Civil Works) Page-1

CHAPTER – I

QUALITY ASSURANCE, QUALITY CONTROL & INSPECTION

1.1 INTRODUCTION

HPPCL is a fast upcoming power generation utility created in Dec 2006 under tCompany Act 1956 for the exploitation of vast unharnessed hydro potential of

expeditiously with quality execution on behalf of Government of HP and HPSEB. It is plann

to harness 3000 MW power generation by March 2017 and 5000 MW by 2022 conforming

all quality norms/standards in practice in a clean & healthy environment.

The Projects for 944 MW are under implementation, 1147 MW is in investigation sta

and 708 MW are in pre-feasibility stage. The Projects under execution are: -

Sawra Kuddu HEP (111 MW) – on ICB (Likely to be completed by December, 2012).

Integrated Kashang HEP (243 MW) – on ICB (Likely to be completed by January, 2013)

Sainj HEP (100 MW) – on ICB (EPC Mode) likely to be completed by August, 2014. Shongtong Karcham HEP (450 MW) – on ICB (EPC Mode) likely to be completed with

60 months.

Renuka Dam Project (40 MW) – on ICB (EPC Mode) likely to be completed within

months.

The construction of a Hydroelectric Project is a mega activity consisting of huge

network comprising many types of construction materials as well as variety of constructi

techniques spanning in a long period of time. Each and every job is required to be executed

acceptable construction quality norms duly conforming to sound design principl

specifications and deployment of good methodology, modern techniques and procedures.

achieve the requisite objectives, it is essential to introduce a result-oriented qual

management system.

Quality in the construction of Hydro Power Projects implies fulfilment of techni

financial and societal needs which the constructed facility is intended to satisfy. For sett

and defining the level of desired quality and achieving it in actual construction, many agenc

get involved to perform different work functions viz management control, technic

administrative and audit aspects.

While the ultimate efficiency of the performance of the project will depend largely

the design and layout, the ultimate health of the project during the life cycle of its operatio

phase will depend largely on the quality adhered in the construction of the project.

The quality of construction is in turn dependent on: -

The quality of construction materials.

The nature and type of controls exercised during their processing and delivery.

The quality of workmanship in laying, finishing, curing etc. of concrete.




The quality in construction has to be achieved by all the parties involved through the

steps required the entire spectrum of construction. The quality control system therefore,

needs to be planned so as to orient the whole range of quality effort on a continuous basis

covering quality assurance and quality control, broadly out lined below, including steps

initiated for its meticulous implementation.

Quality Control/Quality Assurance System and organization: -

Quality assurance including quality control deals with the complete system necessary

to obtain the desited quality needed for a Project to perform a function intended. It

encompasses Design Specifications, Contractual Relationship, Training, Product Control,

Inspection & Testing (for control & for acceptance) and Feedback along with implementation

adherence of Contract work specifications at construction sites and corrective actions

thereon.

Quality assurance (QA) is essentially the process of planning which is necessary to

ensure that the specified qualit y will be obtained. Thus the objective of QA is “Engineering forQuality” rather than inspection for quality. Quality control (QC) on the other hand is the

activity which is carried out to verify such compliance with specified requirements. In thepresent context QC & QA has been viewed together in its entirety.

HPPCL is planning and making functional a separate Quality Control Department

functionally independent of the construction department that ensures that all aspects of

quality assurance/quality control in civil construction are adhered to at all stages of the

Project implementation. The quality cell will comprise of: -

At corporate level – headed by a General Manager at Sundernagar.

At Project level – headed by a DGM/Sr. Manager responsible for QA/QC activities for

different components of civil works.

Main material testing lab at Sundernagar. Central material testing lab at central location at each Project site.

Field MTL at each Project.

It is envisaged that while supervision of the construction should be under the

Construction Wing of the Project authorities, QA & QC personnel and organization would have

authority and organizational freedom to identify quality problem, appropriate solutions and

corrective measures and verification in its implementation.

Organisation responsibility: -

While it is not possible to list each and every activity being undertaken by QA/QC cellfor Quality Control/Quality Assurance, some illustrative area of authorities and

responsibilities are as below: -

To prepare, coordinate, evaluate, document in all aspects of QA system as required by

the specifications.

To analyze all general and special quality objectives defined in the tender.

To establish acceptance criteria.




To approve source of supply of materials in consultation with construction wing

per technical specification, design, relevant Indian/International code of pract

requirements.

To advice construction wing to accept or reject material and evaluate workmanship

consultation with the Design wing of the Project.

To perform regular inspection and surveillance to verify/compliance to

requirements.

1.1.1 Orientation and training of construction supervision & quality control staff: -

A capable and functional construction supervision (CS) and Quality control / Qual

assurance (QC/QA) team is needed to ensure implementation of contract specifications.

achieve this objective, intensive training needs to be given to all related staff

construction/quality control in suitable batches covering specifications for the works to

executed and also the procedure to conduct various tests in the field and laboratori

Recommendations of Indian Standard codes should be explained in the training so as to cov

key construction and QC/QA aspects. The details of training requirements are covered

chapter II.

1.1.2 Laboratory system for testing of input and outputs: -

Looking at the overall quantum of work and the scattered areas of various hyd

power projects of HPPCL, establishment of laboratories (project wise) will form an importa

link of project organization for quality control. The system is required to provide reliable a

accurate testing support to fulfil the objectives. Accuracy and reliability in testing will depe

upon the competence of testing personal, accuracy of apparatus, quality of reagents used, a

maintenance of requisite environmental conditions. Introduction of “Mobile test

laboratory system” will prove to be highly result -oriented. This can be supplemented adequate number of site / field laboratories and central laboratories for material testi

Testing laboratories and their functions are described in Chapter III.

1.1.3 O.K. Card System: -

O.K. card system-cum-check list for the project construction is required to co-ordin

the work of multi-discipline agencies to ensure QA/QC programme for construction

provides a systematic approach towards assuring quality construction and has proved to

practical mechanism for enforcement of technical specifications.

For this purpose, each major work is divided into various activities in propsequence/order of construction and is listed in chronological order of occurrence in the

Card. The cards are maintained in two colours (Pink/Red and Green) to be operated

construction and quality control units separately. During execution of work both the cards a

operated simultaneously and will be kept on record by the Engineer in charge concerned. T

OK Card system along-with specimens is given in Chapter VII.




1.2 OBJECTIVES AND SCOPE OF QUALITY CONTROL

1.2.1 Objectives: -

The objective of quality control management is to collect and process and then

communicate the data related to the quality of inputs and outputs as well as that of the

finished product / item of work to those who are responsible for the quality management.

A programme of quality control seeks to ensure adequacy and uniformity of quality

through the following operations: -

Ensuring that the works are being executed in conformity with the prescribed

specifications and requirements.

Inspection of storage, handling and processing facilities for all the materials in

conformity with the accepted and specified practice.

Monitoring the variations in specifications of the materials and quantities in the

operation of production and in the final product by suitable observations,

measurements and tests.

Analysis of the observed variations by statistical and/or other techniques.

Feed-back of the results of analysis for exercise of control at each stage and to take

corrective steps for maintaining the variations within specified limits.

Indicating expeditiously the possible remedial measures & preventive actions

wherever warranted to ensure execution of works as per drawings and specifications

for effective construction control and continual improvements.

Rejecting, where warranted, the material or the product at any intermediate or final

stage in case acceptance criteria is not satisfied. The rejected material to be removed

from the work site immediately.

Ensuring availability of resources and information necessary to support the operationand monitoring the progress of works.

Thus the objective of quality assurance (QA) is an ‘Engineering for Quality’ rather thanInspection for quality. Quality control (QC) on the other hand is the activity which is carried

out to verify such compliance with specified requirements.

1.2.2 Roles and responsibility matrix

In order to achieve the common goal viz. Quality Construction in the execution of the

project, the roles and responsibility matrix shall be broadly followed by: -

HPPCL Corporate office

Contractor

Project Construction Group

QC/QA Group

Design Group




ROLES AND RESPONSIBILITY MATRIX

HPPCL

CORPORATE OFFICE

PROJECT

CONSTRUCTION GROUP

QC/QA Group CONTRACTO

Set the tone for Quality

Construction.

Organize for construction

supervision.

Organize for QC/QA

supervision.

Adopt means a

methods

construction ensure progr

with quality.

Issue directives on firm

commitment to quality &

strict implementation of

QC/QA programs on

projects.

Convene pre-construction

meeting with Contractor

after award of Contract.

Introduce OK Card

system.

Implement OK

Card system

meticulously.

Maintain pro

construction

sequence a

scheduling.

Establish project

requirements and arrange

Project financing.

Job-specific

Specifications be made

available to all, right up to

the lowest supervisinglevel. Acquaint the staff

fully with technical

specifications of the

contract for strict

implementation.

Acquaint fully with

technical

specifications in

the contractdocuments and

implement strictly.

To eng

requisite

engineering

otherexperienced s

to ens

implementatio

of contr

specifications

and works.

Set organization of field

construction team.

Monitor regularly the

adequacy of contractor’sequipment and plant for

progress, safety and

quality.

Conduct sampling of

inputs and outputs and

get them tested from test

laboratory as per

specified frequency. If not

found satisfactory, inform

to HoP for remedial

measures.

Ensure conducting

of sampling and

testing of inputs

and outputs as per

IS / specified

frequency.

Maintain s

safety, first a

and

housekeeping.

Set organization of QC/QA

team.

Administer contracts

strictly.

Get the lab testing

equipmentcalibrated

regularly.

Strict complia

of technspecifications.

Enforce housekeeping

and site safety by the

contractor.

Ensure quality and

safety.




Approve training

programmes for

construction supervision

and quality control

personnel on QC/QA

aspects.

Conduct regular progress

& quality review meetings

with contractor.

Acquaint fully with

testing procedures

and standards.

Filling of OK

Cards and

presenting to

construction

staff.

Ensure that QC labs aremanned by competent

personnel well versed in

conducting tests on inputs

/ outputs and that the

tests are reliable.

Involve Geologist &

Geotechnical

instrumentation expert on

geotechnical aspects /

problems.

Communicationand feed back of

deficient quality

work be very

prompt, work be

stopped, if

necessary and

construction team

informed about

violation of

specified

procedures bycontractor.

Planning anddeployment of

construction

materials, plant

and equipment

consistent with

progress, safety

& quality.

Ensure regular payment

to the contractor for

works done.

Ensure preparation of “Asbuilt drawings” as thework proceeds.

Fulfilling

contract

commitments

competently and

faithfully;

performing on

schedule.Arrange conducting of

quality audit of project

works periodically

through an Internal Audit

team.

Encourage contractor to

get his nucleolus

personnel also trained on

QC/QA aspects.

Compile quality

control data on

continuing basis

preferably

computerized.

Implementation

of change orders.

Constructing

project facilities

as specified by

contract

document.

Maintain video graphic &

photographic record of

works.

Use Control charts

as dynamic tools to

monitor QC of

works as well asmaterials like

cement/ concrete/

steel/ mortar etc.

Avoid conflicts.




Have close liaison

with construction

team and

contractor on

QC/QA aspects.

Inducting

experienced

supervisory

personnel

construction.

Initiate action for ISO

9001:2000 certification &formulation of Quality

Policy of HPPCL.

Keep abreast with

improved quality

control

procedures, state-

of-the-art

equipments &

techniques for

possible

deployment.

For setting up the framework of QA/QC system, the key roles of different groups are give

under: -

Key Roles of Design Group

Furnish construction drawings/approval of designs & drawings and related adequateunambiguous inputs well in time and as per L2 schedule.

Provide prompt advice on design and design related quality aspects.

Review, validate, approve and verify job-specific technical specifications and acceptancriteria.

Inspect works regularly to ensure proper implementation of design philosophy and qualrelated aspects in construction.

Provide guidance to project teams on technical elements of contracts and change orders.

Review adequacy of contractor’s infrastructure, job facilities and construction pldeployment in achieving quality construction.

Maintain close liaison with Geologists, experts and Consultants for solutions to construct

stage problems after proper documented reference from field units.

Systematic reviews and verifications/validations to ensure that the resulting productcapable of meeting the requirements of specified application or intended use.

Key Roles of QC/QA Group at the project

Develop the project QA including policy statement and quality objectives based on inp from the construction group.

Perform regular inspections and surveillances to verify compliance to QA requirements.

Analyze all general and special quality objectives defined in the contract.

Establish acceptance criteria.




Prepare, coordinate, evaluate and document all aspects of QA system as required by thespecifications.

Recommend & participate in the selection of material testing laboratories.

Advice construction group accept or reject material and evaluate workmanship.

Evaluate test/inspection data and formulate proposals for corrections and/or improvements.

Review the internal QA programmes and quality of work of the contractors, suppliers and

material testing labs as the construction work progresses. Prepare QA manual.

Key Roles of Quality Assurance Group in contractual situations

Pre-bid stage: Identification of quality system requirement tests & inspection requirements

including QA practices, national & international standards etc. and subsequently theirinclusion in the bid documents.

Post-bid stage: Review of technical bids with respect to QA requirements, inspection and

testing requirements etc & inform the contract group regarding clarifications to be sought from the bidders in case of any such need.

Post-Contract Award stage: Review of contractor’s agreed quality plans with respect to

specification requirements/national & international code requirements/good engineering practices etc.

Key Roles of Construction Group

Approve sources of supply of materials in consultation with the QA/QC group.

Get materials tested and to approve or reject the same.

Supervise workmanship and inspect work in progress.

Identify and resolve quality problems jointly with QA/QC group.

Key Roles & Obligations of the contractor

Entire responsibility of adopting the correct construction procedures.

Selection of proper materials.

Employment of experienced and knowledgeable personnel. Operation of the plant & equipment to produce the works and satisfying the standards

regarding quality.

Provide satisfactory sampling and test facilities and labour for easy and quick collection ofadequate quantity or representative test samples.

1.3 QUALITY- CONTROL MANUAL

Quality Control Manual 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 QC organization;duties and responsibilities of QC personnel; QC laboratory system; OK cards; monitoring

through Control Charts; control on materials and workmanship; tests on materials; important

specifications; quality audit & quality improvement; standards to be adopted for materials

and works; frequency of testing and reporting; compilation of QC data and statistical analysis,

documentation, feed-back, inspections etc. All these aspects are covered in subsequent

chapters.




This Quality Manual covers the aspects of QA & QC in Project construction for: -

Use of cement and cement concrete.

Erection and commissioning of Hydro Mechanical works.

1.4 CONFIGURATION OF QUALITY MANAGEMENT SYSTEM

The primary concern of HPPCL is to offer the quality of its products and services so as to

Meet a well defined need & purpose.

Satisfy end-user’s expectations.

Comply with applicable standards & specifications.

Comply with statutory & other requirements of society.

Be made available at competitive prices.

Provide at a cost which will yield a profit.

An effective quality management system designed will satisfy end-users’ needs aexpectations while serving to protect organization’s interests.

The configuration of a well structured quality system is depicted as below: -

Dotted lines shows Feedback loop for QC/QA

Quality in construction must be achieved by all the groups involved through the step

required in the entire spectrum of construction.

In the above configuration, inspection and product control shown under the contrac

relates to workmanship as well as plant, machinery and construction equipment.

HPPCL Internal Quality Audit Team

Construction

Group

Corporate

QA/QC Group

Design

Group

Contractor

Organizes for Quality

in Construction

Inspection

Product

Control

Site A C Unit

Inspection Inspection Testing




1.5 Definitions

Quality: - The totality of the features and characteristics of a Product or service that bear onits quality to satisfy stated or implied needs.

Quality Policy: - The overall quality intentions and direction of an organization as regardsquality as formally expressed by the top Management.

Quality Management : - Important aspects of the overall Management function thatdetermines and implements the quality policy.

Quality Assurance: - All those planned and systematic actions necessary to provideadequate confidence that a product or service will satisfy for given requirements of quality.

Quality Control: - The operational techniques and activities that are used to fulfilrequirements for quality.

Quality System: - The organizational structure, responsibilities, procedures, processes andresources for implementing Quality Management.

Quality Plan: - A document setting out the specific quality practices, resources and sequenceof activities relevant to particular product, services or Project.

Quality Surveillance: - The continuing monitoring and verification of the status of

procedures, methods, conditions, processes, products and services and analysis of record inrelation to stated references to endure that specified requirement for quality are being met.

Quality System Review: - A formal evaluation by top Management of the status andadequacy of the quality system in relation to quality policy and new objectives resulting fromchanging circumstances.

Inspection: - Activities such as measuring, examining, testing, gauging one or morecharacteristics of a product or service and comparing these with specified requirements todetermine conformity.

Concessions: Waiver: - Written authorization to use or release a quantity of material,component or stores already produced but which do not confirm to the specifiedrequirements.

Production Permit : Deviation Permit : - Written authorization, prior to production orbefore provision of a service to depart from specified requirements for a specified quantity or

for a specified time.

Reliability: - The ability of an item to perform a required function under set of conditions forstated period of time.

Specification: - The document that prescribes the requirement with which the product orservice to confirm.




CHAPTER-II

ORGANIZATIONAL SETUP

2.1 Quality control unit formation

I. The personnel connected with quality control assignments must possess the relev

expertise and competence to perform specific tasks connected with quality control wor

and should be well conversant with testing of construction materials. The objective

quality control should be clearly understood by them in letter and spirit so as to help

quality construction and to achieve high order of quality as laid down in specifications

controlling various factors responsible for deterioration in quality, investigating reaso

there for and suggesting ways and means for improvement.

II. Quality Assurance organization both at corporate and project level should be structured

systemize all the activities during the various stages of design, engineering, constructi

procurement, manufacture, assembly, erection and commissioning so as to ensure th

quality and reliability are built in all systems of construction, materials and equipments.

III. Job Analysis

For hydro power projects, number of tasks is to be carried out for QA and QC. The tasks a

basically grouped as under: -

1. Testing i) Physical

ii) Chemical

2. Inspection i) Workmanship

ii) Plant & Machinery 3. Documentation i) Input Data ii) Test Results iii) Report/Record Up-Keeping

4. Evaluation & Review i) Testing

ii) Inspection

IV. Manpower Planning

Identifying the work to be performed in each task provides the basis for manpow

planning. Based on the forecasts in respect of demand and supply, the manpower plan sho

be prepared for each project and ensure adequacy of availability of human resources. Tplan should set out;

The number and types of personnel required and when they are needed.

Availability problems and how they can be overcome.

Strategy governing identifying suitable personnel and placement in QA/

programme.




To achieve proper and independent quality, the Quality Control formation in HPPCL

should consist of:

1. At Corporate Level:

An independent QC unit headed by GM (QC/QC) at Sundernagar under the control of Director

(Civil). Testing lab at Naulakha, Sundernagar desi gnated as “ Main Centre Lab” will functionunder the control of GM (QA/QC) and will be well equipped with all necessary apparatus forcarrying out preliminary as well as special Quality Control Tests.

The GM (QA/QC) at Sundernagar shall have two or three Sr. Managers (E6 level), in chargeof Quality Control of construction activities of various projects.

Each Sr. Manager shall have two Engineers each (E1 to E5 level) to look after the work.

2. At Project Level:

Every Project shall have a separate QC unit headed by DGM/Sr. Manager (E7/E6) who shallreport to HoP/GM (Project) and GM (QA/QC), Sundernagar for the purpose of effective

Quality Control.The jurisdiction at the project site shall be sub divided in a number of units and each unit isto be put under the charge of an Engineer (E1/E6 level). DGM/Sr. Manager (QC) shall makeall arrangements for demarcating the areas of operation of every quality control staff andissue a duty chart for each member after approval from the GM (Project).

Central Field Laboratory will be situated at important nodal point which shall cover all the

adjoining works and will be under Sr. Manager (QC). Site laboratories as per requirement in

the field shall be maintained by concerned site in charge (Construction) and also utilized by

the Engineers (QC) for carrying out necessary tests.

V. One of the fundamental principles to be understood and kept in mind is that the overallresponsibility for achieving construction quality in each project rests with the execution

unit and the construction staff shall be fully responsible for quality of work. Requisite

assistance is to be provided by the QC Staff for ensuring construction quality.

2.2 Functions of Quality Control Units

The main function of QC unit is to have independent checking and control of works. Since

the works in the projects are of scattered nature, the quality control units can not exercise

concurrent quality control, but it has to be so planned that these units act in such a manner

that necessary quality control requirements are fulfilled jointly with the execution staff.

It will be the responsibility of quality control staff to ensure that all-requisite tests as per

IS/relevant standards and specifications are carried out at site/field or laboratories. The

quality control units will carry out periodic inspections of works and conduct field tests so

that any deficiencies found in the execution of works are properly brought to the notice of

concerned authorities and execution staff for taking corrective measures.




The various levels of QC/QA personnel in lab system can be categorized as: -

Operational

Supervisory

Middle Executive

Executive

Management

The broad indications of functions and responsibilities of quality control units at ea

level are given as under, which may be supplemented by issue of any further detai

instructions by Director (Civil) and/or GM (QC)/HoP, from time to time, as required for

project-specific.

Operational level:

Collecting/receiving samples, recording sample particulars, preparation of test sampl

carrying out tests and recording of test data.

They will generally carry out routine testing and will be responsible for ensuriappropriate operational condition for the equipment and instruments.

Supervisory level:

Overseeing and ensuring that routine tests are carried out as per prescribed standar

carrying out tests requiring special skills, proper maintenance of test records & preparation

test reports including analysis of results and stating conclusions.

Middle executive:

Receive test results, check accuracy, validity & timeliness of testing schedule, certifying t

accuracy of test results, process data as required by the management, safe custody

documents, ensuring maintenance and calibration of testing equipment, planning t

programme of work and assigning duties to operative & supervisory levels.

Executive level:

Overall charge of QC/QA communication in vertical and horizontal levels, organizi

documentation, assigning data analysis for documentation, coordinating with cent

laboratory and other parallel laboratories, personnel development of staff including train

needs, indexing & standardization of records, preparation of management information

reports, sorting out data for archival purposes, ensure computerization & maintenance

short term & long term records.

Management level:

Ensure that the objectives of QC/QA are fully served at other four levels, interact with t

construction wing and the contractors on QC aspects particularly when quality problems a

not satisfactorily resolved and to monitor the QC/QA organization for its effectiveness.




The above personnel pattern is stated in general functional term, the following points

shall, however need to be given particular attention: -

The QC units should monitor that all the required tests are carried out before start of work aswell as during and after execution. At least 10% tests are to be conducted by the qualitycontrol units for reliability of the results and counter checking.

The QC units should ensure that all arrangements for carrying out routine field tests in the field laboratories are duly made including provisions and up-keep of equipments, personneletc. and record of these field tests in prescribed formats are maintained. They should checkthis record and also sign in the relevant registers in token of their inspection. They shouldconduct field tests whenever they visit site of construction work and record results of suchtests in the registers maintained for the purpose.

The QC unit is empowered to take independent inspection/supervision to identify quality problems and to recommend appropriate solutions/corrective measures toHoP/Construction Wing to pass the necessary instruction to the Contractor for its properimplementation.

Inspection book should be maintained at site wherein remarks should be recorded by quality

control staff whenever they visit the particular site and the same should be noted forcompliance by the construction unit. They should specifically record any deficiency observedto bring the same to the notice of appropriate authority through remarks in the inspectionbook or inspection note. The execution staff shall ensure compliance of such deficiency andintimate to the concerned officer of Quality Control Unit.

The GM (QC) shall ensure at least one test check quarterly of all the works costing more than

` 100lacs. This does not preclude him for conducting more than one test check of any

important work for which frequent checking is to be carried out.

The test checks shall be thorough to ensure the quality of work and shall include but not

limited to: -

Tunnel/Cavern excavation and support elements including Geotechnical instrumentation performance monitoring.

Observation of densities and moisture contents of earthwork.

Fineness modulus of sand, grading of sand and coarse aggregates.

Checking of mix-design and water-cement ratio for concrete.

Checking of concrete lining work/steel liner work/masonry work.

Safety measures.

Any other requisite test checks for project-specific.

2.3 Training Requirements

The human resources development plan will include programme for training and re-

training the QC/QA employees for improving their performance in their present position or

preparation for future positions.

The plan will also cover training of fresh entrants in QC/QA units.




The plan for training-needs should include: -

Overview of quality assurance and quality control in projects.

Conceptualization of activities that will meet needs.

Identify personnel for training & organize in-house training.

Identify existing training centres with appropriate programme and reputation for effect

training.

Liaise with training institutions and monitor the activity.

Coverage for evaluation and feedback.

An outline on the contents of training requirements related to QC/QA in concr

construction, designed to suit the officials at operational and supervisory level, is given

under;

A.

General

Purpose of training.

Background of QC/QA.

Importance of testing.

Care of equipment.

Certification.

Calibration.

Standards and references.

Documentation and communication.

B.

Materials

Cement and its properties.

Aggregate and its properties.

Admixtures for concrete.

Properties of fresh concrete.

Properties of hardened concrete.

Tests on cement, aggregates and concrete.

Steel.

C.

Concrete Testing

Fundamentals of concrete and concrete materials.

Field tests.

Sampling.

Slump. Moulding and initial curing cylinders.

Measuring air and concrete temperatures. Air content.

Unit weight. Handling and transporting cylinders.




Laboratory tests.

1.

Cement

Physical characteristics. Chemical characteristics.

2.

Aggregates – Coarse and Fine

Unit weight (dry moulded or loose). Sieve analysis (including fineness modulus).

Specific gravity and absorption. Moisture content (including Chapman flask).

3. Concrete Cylinders/Cubes

Curing (standard and field curing).

Weighing, measuring, capping and testing.

D.

Inspection

Aggregate crushing plant Overall inspection i/c stacked material in bins.

Batching Plant (i/c Ice

Plant)

i) Monitor batching & mixing.

ii) Aggregates, Cement, Water, Admixture.

Project i) Monitor conveying concrete to forms (direct discharge,

bucket, buggy, pump etc.).

ii) Observe formwork constructions and placing of

Reinforcement.

iii) Observe curing and protection.

E.

Workmanship

Batching, mixing and transportation of concrete.

Placing, compaction and finishing of concrete.

Curing of concrete.

Inspection of machinery and equipment.

Tracking of non-conforming items.

F. Information System and Documentation

Data records, results and reports.

Communication systems.Decisions and controls.

Custody of documents.




CHAPTER-III

TESTING LABORATORIES & THEIR FUNCTIONS

3.1 Objectives

The Laboratory system, in addition to evaluate and monitor the inputs and outpu

would also evaluate and monitor the workmanship as well as construction plamachinery and equipment. This would, thus be a testing as well as inspection system

The quality of output i.e. the concrete/shotcrete in place will be accomplished main

by in- situ and laboratory testing.

The main objective of the laboratory system is to provide reliable and accurate testi

support and competent inspection to aid QA/QC.

Reliability and accuracy of results of material-testing will depend upon the followi

parameters.

Abilities of the testing personnel

Quality of reagents and materials used Accuracy of the apparatus and equipment

Maintenance of special environmental conditions for the material tested.

Environment in which the tests are to be conducted.

Strict controls are required to be adopted to obtain the true value with respect

these four parameters. The following guidelines need to be followed for this purpose

a) The laboratory shall operate as an internal quality assurance programme.b) Measuring and testing equipment used in the laboratories/field shall be calibrated bef

being put into service and thereafter at regular pre-set intervals.c)

The environmental conditions in which the tests are undertaken shall be maintained per those specified in the relevant standards.

3.2 Laboratory Quality systemThe laboratory system shall operate an Internal Quality Assurance Programm

(IQAP) to the type, range and volume of work performed.

IQAP shall be documented in a manual which should be available for use by t

laboratory staff. This quality manual shall contain information regarding.

a)

The structure of the lab.b) Operational & financial duties and services pertaining to quality so that each member

the staff knows the extent and limits of his responsibility.c) General quality assurance procedures.d)

Quality assurance procedure specified for each test, as appropriate.

e)

Satisfactory arrangements for feedback and corrective action whenever testdiscrepancies are detected.

f) Procedure for dealing with technical complaints.

The laboratory quality system shall be systematically and periodically reviewed a

competent level to ensure continued effectiveness of the arrangements and correct

action initiated. Such reviews shall be recorded together with details of any correct

action taken.




3.3Set-up of laboratories

Main Central Laboratory at Sundernagar

The functions of this QA/QC unit shall be broadly as follows;

Ensure strict implementation of QA/QC programmes on all projects under execution.

Keep close liaison with project QA and construction teams. Compile quality control data for each project on continuing basis.

Arrange conducting of quality audit of various projects periodically through the quality audit group.

Acquaint fully with contract documents & technical specifications as well as testing procedures and standards.

Establish and suggest project quality improvements from time to time.

Identify training needs of QA / QC staff of HPPCL.

Arrange conducting of sampling and testing of inputs and outputs in the Main Central Lab at

Sundernagar.

Updating of Main Central Lab with the state-of-the-art equipment from time to time.

Any other related task assigned by Director (Civil).

Each HPPCL hydro power project should have laboratories (level-wise) during

construction, as under: -

a)

Central field laboratory (level-1).b) Site laboratory for diversion & intake structures, de-sanding arrangement & HRT (level- 2).c) Site laboratory for Power House & TRT, Surge Shaft, Pressure Shaft / Penstocks (level-2).d) Testing units for Batching & Mixing plants and adits (level-3 including mobile units).

A typical hierarchy of laboratory system is given below: -

TYPICAL HEIRECHY CHART FOR LABORATORIES

CENTRAL LABORATORY

*Field Testing Units for Batching, Mixing, Screening & Crushing plants, Adits etc. (Level-3)

Site Lab for Diversion &

ntake, Desanding & HRT

Site Lab for

PH, TRT, SS &

Level-2 Level-2

*UNIT-I *UNIT-I *UNIT-I *UNIT-I

Level-1




3.4Functions of Central Field Laboratory (Level-1)

The central laboratory will be a well-equipped testing laboratory at the project site wh

will be equipped with all necessary apparatus for carrying out preliminary tests a

quality control tests on various construction materials. It shall be called level-1 laborat

for the entire project.

The role of this central laboratory would essentially be a coordinating and referlaboratory as well as laboratory for special tests & studies.

The central laboratory will be so located as to enable close co-operation with the site

site laboratories.

The functions of central laboratory shall be as under: -

Coordinate the management and quality systems and take all steps to ensure accuraand reliability of testing in all laboratories.

To document an internal QA programme within the laboratories to assure the validitythe reported results.

Organize inter-laboratory proficiency tests, and ensure timely calibration of testi

equipment. Interact with outside laboratories for tests to be conducted outside the project laborat

system. Design the concrete mix including review of mixes and conducting trial batch mix

proportioning shotcrete mixes; and selection & dosing of admixtures and additives. Investigate all failures and carry out diagnostic tests. To be proficient to carry out all the tests those are conducted in all level-2 & leve

laboratories and ensuring reliability & accuracy of level-2 & 3 lab tests. Undertake all those tests including *special tests which are not covered by level-2 a

level-3 laboratories.

*The special tests shall include but not limited to the following: -

Optical microscopy of samples.

Non-destructive testing / evaluation of concrete.

Tests including core testing, thermal diffusivity of materials, creep, shrinkage, modulus

elasticity, rock mechanics testing & permeability tests etc.

Ultrasonic pulse velocity & rebound hammer tests.

Inspection and testing of pre-stressing, grouting, deflections and related operations.

Installation of testing instruments in the structures, maintenance, recording

readings and analysis of data. Load testing of structures where required.

Inspection of trend reports and statistical analysis of data.

Identify and arrange archival needs of materials.

Identify and organize training needs for Quality control.




3.5Functions of site laboratories (Level-2)

The level-2 site laboratories as indicated in the hierarchy chart under 3.3 above shall be

responsible for the following functions: -

To be proficient to conduct all tests that are identified to be carried out by the respective fieldtesting units (Level-3) as described in 3.6 hereinafter.

To perform the testing and inspection necessary for the level of the QA programme requiredas per specifications.

Carry out tests on concrete producing materials like cement, aggregates, water, ice,admixtures, curing compounds, reinforcements etc. at required frequency and as persampling plan.

Design the concrete mix including review of mixes and conducting trial batch mixes; proportioning shotcrete mixes; and selection & dosing of admixtures and additives.

Monitor batching, mixing, transportation, placing and compaction operations.

Inspection of workmanship in concrete constructions including joint preparations.

Monitor compliance of quality trends and point out instances of non-compliance for effecting

necessary corrective measures.

Conduct compressive strength tests of site concrete on cylinder/cubes specimens.

Conduct accelerated strength tests on concrete.

Conduct tests for analysis of fresh and hardened concrete as well as shotcrete mixes.

Conduct tests for in-situ evaluation of efficacy of curing compounds.

Carry out statistical analysis of data, and document the trend reports.

Provide all testing report-results in time.

3.6Functions of field testing units including Mobile units (Level-3)

These laboratories are to carry out daily routine tests on soils, filter materials, ingredients

of concrete and mortar of the samples collected by the construction staff and report theresults to the concerned quality control unit in the prescribed Performa pertaining to

following tests & inspections:

A. SOILS & EARTH WORK

Density, moisture content and compaction efficiency.

Sieve analysis.

Proctor density & OMC.

Atterberg’s limits.

Specific gravity.

B.

SAND (Quarry site and sand mill plant)

Gradation analysis, silt content and Fineness Modulus.

Bulk age.

Organic impurities through “Quick Color test” .

Moisture contents.




C.

CEMENT

Setting time by vicat needle test.

Strength of cement.

Casting of cubes for strength.

Fineness by Sieve.

Heat of Hydration

D.

COARSE AGGREGATE (Quarry site and sand mill plant).

Grading and Moisture contents.

Physical Properties.

Specific gravity.

Impact Value, Soundness, Crushing Value, Flakiness.

E. CONCRETE BATCHING AND MIXING PLANT

Caliberation of batching plant.

Checking dispensing/feeding system.

F. FRESH CONCRETE & MORTAR

Mix proportion, measurement of temperature variation in mass concrete due to heathydration through placing temperature sensors, casting of concrete/mortar, cylinders/cu

for compressive strength and density.

Slump test.

Water cement ratio, unit weight & slump test for workability.

Physical properties of ingredients & silt content of sand.

Casting of concrete & mortar cube/cylinder specimens at recommended frequency fstrength tests.

Compressive strength & density tests of concrete & mortar prior to placement aimmediately after initial set.

Mix Proportions.

Consistency for placement of concrete.

Measurement of temperatures of concrete and air at mixing plant as well as placing site.

Determination of air content in concrete at mixer as well as the worksite.

For concrete and masonry, the strength of concrete and mortar has to be as specified

the specifications.

Laboratory has to design the proportions of different ingredients through tests for

specified strength. The proportioning shall be done by weight. It should be co-related wvolume for volumetric batching of concrete where quantity of concrete to be placed is of sm

magnitude. Volume batching may be allowed where weight batching is not practical a

accurate bulk densities of materials to be actually used in concrete have been established.

Allowance for bulking shall be made in accordance with relevant IS. The mass-volu

relationship shall be checked at periodical frequency to ensure that specified grading

maintained.




When controlled concrete is specified, it is essential that mix is to be designed in the lab.

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 commencement of work. This would facilitate in

furnishing proper proportion of the mix for adopting in the field and also it entails adding or

reducing cement content based on the strength of the cement.

G.

BOULDER SAMPLE

Water absorption.

Dimensions.

Physical properties including weathering etc.

Specific gravity, impact value, soundness.

H.

BRICKS

Dimensions & physical properties including water absorption.

I. STEEL SAMPLES

Physical and chemical properties.

J.

HARDENED CONCRETE SAMPLE

Strength and Ingredient Proportion verification.

K.

SHOTCRETE

Mix proportion

Water cement ratio & unit weight.

Physical properties of ingredients & silt content of sand.

Slump test, temperature measurement & subsequent casting of panels & cutting core/beamspecimens at recommended frequency for compressive/flexural strength.

Rebound tests (Total rebound/fiber rebound for SFRS).

L.

ADMIXTURES/ADDITIVE SAMPLES

Physical and chemical properties

Record of daily activities/tests will be maintained at site in the registers such as: -

Inspection Register.

Density Register.

Registers for sieve analysis of coarse & fine aggregates.

Cement Consumption Register. Slump Test Register for concrete.

Registers for compressive strengths of cement, concrete & mortar. Daily progress register- progress to be compared with consumption of various

ingredients including cement. Daily weather registers including temperature and relative humidity of work sites.




3.7Improved devices for quality control

It should be planned to introduce improved devices for achieving speedy and efficient quacontrol.

Monitoring the characteristics of fresh concrete is important from the point of view of quacontrol. The 28-day strength of concrete is the criteria for acceptance and is the basisquality evaluation but we have to wait for 28 days to get the results of compressive streng

of concrete cubes/cylinders. Even the accelerated compressive strength tests taconsiderable time.

Portable electronic devices, commercially available now, have made it possible for rapid osite measurements of slump, temperature, water-cement ratio (the most important facinfluencing the strength of concrete) and the likely 28-day strength of fresh concrete mixSoftware supplied with the electronic unit also prod uces ‘quality control certificates’ ba

on the measurements taken by this electronic unit. This evidence of the properties of concr gives the site QC/QA Engineer, the confidence to accept or, if necessary, reject the concrmix before it is placed.

Central Field laboratory should be equipped with such a portable electronic unit w

software. On embankment construction and compacted earth fill placement, it should be planned

procure an engineering device of the type “Nuclear Gage” to enable much more rapid aeconomic compaction and quality control than the conventional methods, without any lossaccuracy. Such a device is capable of quickly computing and displaying wet density, moistcontent, dry density, and percentage of compaction in terms of Proctor density.

The central Field laboratory should be equipped with such Nuclear Gage Devices.

3.8Scope of inspection and testing facilities:

These are illustrated as under, in general: -




CHAPTER-IV

DUTIES & CONTROL OF LABORATORIES

4.1 Duties of in-charge of laboratory: -

To ensure proper up-keep and maintenance of all laboratory equipment in the

laboratory.To ensure proper up-keep of records of all samples being tested in the laboratory as per prescribed norms and communication of the results to the concerned.

To supervise the testing works in the laboratory and to personally check the tests to theextent of minimum 25%.

To prepare fortnightly review of all the test results and submittals to the concernedQuality Control & Construction units.

To get conducted the research work (as may be assigned) with the assistance of ResearchOfficers.

To ensure that the construction staff sends the material samples to the lab much inadvance as the Central laboratory & the site/field laboratories have to conduct tests for

the suitability of materials well in advance of the actual execution of work.

4.2 Duties of Assistant engineers/Assistant research officers/research assistants

(laboratory): -

They shall perform important tests as mentioned below: -

A.

CEMENT

Fineness by Blains.

Normal Consistency. Setting time.

Soundness.

Specific gravity. Compressive strength.

Adulteration test.

B.

SAND

Sieve Analysis & Fineness modulus. Test for organic impurities in silt & clay.

Decantation test for silt. Specific gravity.

Unit weight and bulkage factor.

C. COARSE AGGREGATE

Sieve Analysis and gradation. Specific gravity.

Water absorption. Examination of deleterious materials.

Crushing strength.

Impact.

Abrasion.

Flakiness index.

Alkali Silicate reactivity.

D.

CONCRETE

Consistency: slump or compaction factor. Compressive strength.

Air content.

Yield per unit quantity of cement.

Mix design tests.

Cement content.




E.

MORTAR

Consistency. Compressive Strength.

Yield per unit quantity of cement. Cement Content.

F.

SOILS

Gradation (Grain size analysis).

Consistency limits.

Porosity & Void ratio.

Specific gravity.

Swell pressure.

4.3 Duties of laboratory technicians/junior research assistants.

Assist Assistant engineers/Research officers in the laboratory.

Perform tests in the laboratory such as: -

Compaction tests. Limit tests.

Analysis of fine & coarse aggregates. Silt in fine aggregate.

Slump test.

Collection of samples of concrete and mortars for filling moulds for compaction test.

4.4 Duties of laboratory attendants.

Keep instruments clean.

Assist AEs & laboratory technicians in conducting tests.

Prepare samples for test.

Arrange samples systematically.

4.5 Control of test equipment for inspection, testing and measuring.

The identification, calibration, and adjustment of all test equipment and devices requir

for inspection and measuring will be done at prescribed intervals against certif

equipment having a known valid relationship to nationally recognized standards.

The equipment will be capable of controlling the delivery of material for weighing so th

inaccuracies in feeding and measuring during normal operation will not exceed 1% water and 3% for all aggregates.

Periodical tests will be made at least once in a month in case of equipment for measur

water, cement, admixtures, sand and coarse aggregate. Other measuring equipments w

be tested once in a year unless some defects are noticed earlier, in which case these will

attended immediately.

Documents will be established and calibration procedures will be maintained with

following details: -

Equipment type. Identification number. Location. Frequency of checks. Check method. Acceptance criteria.

Action shall be taken for unsatisfactory results to ensure that the inspection, measuri

and test equipment are capable of giving the required accuracy and precision.

4.6 Duties of field engineers in relation to quality of works:

The duties listed below have been indicated broadly. Other jobs assigned in relation

quality control shall also be ensured during execution of work.




Sr. No. CONSTRUCTION ENGINEER QUALITY CONTROL ENGINEER

1. Shall ensure that: -

i) The layouts/mark outs/setting out/

alignments of the area to be tackled,

on the ground or underground, areproperly given.

ii) Profiles, lines, grades, dimensions,

probe holes, support elements,

shotcrete, drainage, ventilation,

lighting, shuttering, centring,

concreting, lining, reinforcement etc.

are provided as per drawings and

technical specifications.

iii) The Pre levels/foundation levels

are recorded, and mark-out for

excavation is perfectly given as perdrawings.

iv) All safety measures as per

specifications are provided strictly.

Shall check: -

i) All the layouts/mark outs/setting out/

alignments as well as check that the

profiles, lines, grades, dimensions, probeholes, support elements, shotcrete,

drainage, ventilation, lighting, shuttering,

centring, concreting, lining, reinforcement

etc. are being provided as per drawings and

technical specifications.

ii) Shall check that all safety precautions as

per relevant Safety Manual and other

related provisions are being adhered to.

iii) To inform the Construction Engineer to

rectify the defects & deficiencies, if any.

2. Shall ensure that adequate

construction equipment like dozers,

dumpers, tippers, boomers, loaders,

gentries, mixers, vibrators,

compaction equipment and

arrangements for curing/dewatering

are arranged before commencementof any work.

Shall check the adequacy of all the

construction equipment and

curing/dewatering arrangements before

start of work as well as during execution.

3. Shall ensure that sufficient quantities

of input materials as per agreement/

specifications are made available at

site of work and arrange testing

equipment, men and material required

for conducting field tests, sending

samples of input materials for testing

to central lab and field laboratories as

per norms.

Shall conduct/get conducted by different

laboratories the field tests on input

materials as per norms and record the

results, as prescribed, and inform the

construction engineer to rectify the defects,

if any.

4. Shall write OK Cards after the area is

ready for commencement of the work

and inform the Quality Control

engineer and seek his consent on the

OK Card to start the work.

Shall check and write the OK card and

record the deviations/defects, if any or

otherwise record the final OK and inform

the Sr. Manager (QC) permitting

commencement of the work.




5. Shall ensure adequate care during

underground excavation relating to

drilling & blasting operations,

ventilation, lighting, drainage, fire

fighting, communication & access etc.

as specified.

Shall supervise and ensure that theexcavated muck is dumped and duly

protected in the specified dumping

areas complying with the norms of

Pollution Control Board/other

regulations in force.

Shall make regular checks relating to ca

being taken during underground excavat

& proper muck disposal and inform t

construction engineer to take prevent

measures in case discrepancies are notice

6. Ensure that correct quantities of input

materials as per mix design, finalized

in the testing laboratory are fed into

the mixers/batching plants and also

ensure specified mixing time.

Shall check the feeding of input materi

and the mixing time and suggest t

quantity of water depending on

moisture content of sand, as and wh

required.

7. Shall ensure proper vibration,compaction, rolling, construction

joints, curing of concrete etc, during

execution of day to day work. Also

provide men and materials required

for extracting samples of finished

product for quality control personal.

Shall conduct Density tests of earth wogradation of material, slump test, core d

test and extract field samples of materi

and finished products to be sent to differ

laboratories for testing.

8. Shall ensure proper curing of samples

extracted till the curing time is over

and to make arrangements to send the

samples to testing lab.

Shall help the construction engineer

proper handling / transport of samples

the lab.

9. Shall ensure timely green cutting ofconcrete with proper air-water gun;

nicking & chipping (wherever so

warranted) so as to prepare the

surface for next concrete lift for

effective bend at the lift / construction

joints.

Shall check that the preparation of tsurface is adequately done for starting t

next lift.

10. Shall ensure proper curing/watering

and allow removal of shuttering only

after the time prescribed in the

specifications and see that the

surfaces are finished to the plumb/straight lines etc. after removal of

shuttering.

Shall check the adequacy of curin

watering and that the final surfaces

finished neatly to the plumb / straight lin

etc.

11. Shall maintain mark-out register, OK

Card files, Load register, Daily

progress register, Inspection register,

Cement consumption register etc.

Shall maintain registers of all the field te

conducted.




Sr. No. DGM/SENIOR MANAGER

CONSTRUCTION

SENIOR MANAGER

QUALITY CONTROL

1. Shall supervise, check, advice and

instruct his subordinate construction

engineers regarding discharge of their

functions properly.

Shall supervise, check, advice and instruct

his subordinate quality control engineers

regarding discharge of their functions

properly.

2. Shall intimate the Senior Manager(QC) regarding signing of agreement

for starting of any work and supply

copies of all contract documents,

drawings, specifications, construction

programme etc.

Shall maintain copies of approved designs,reports, contract documents, drawings,

specifications, construction programme,

extracts of inspection notes etc. and shall

see that his subordinates go through these

documents.

3. Shall ensure that all ingredients of

concrete, shotcrete, masonry etc. have

been got tested before use. Shall see

that the soils are tested for various

properties like OMC, MDD etc. before

starting of foundation & embankmentwork.

Shall verify that test results are available

before starting of any work and also during

execution of the work.

4. Shall ensure that all the machinery/

equipment/devices/instruments

being used by the contractors are got

periodically calibrated.

Shall reassure the upkeep and calibration of

equipment.

5. Shall ensure that OK Cards are

written/ authenticated and kept at site

of work before starting of any work.

Ensure rectification of work before

releasing payments.

Shall inspect and sign the OK Cards during

field visits. Shall point out defects in

construction and suggest remedies for

achieving good quality construction.

6. Shall order suspension of work if anydefects are noticed or reported by

Quality Control department and

resume the work only after

rectification of defects in the presence

of Quality Control engineers.

Shall order stoppage of work if majordefects are noticed or reported by Quality

Control engineers and intimate his

construction counterpart to see that defects

are rectified immediately.

Also defects noted during construction are

to be reported to the GM (QC) & HoP.

7. Check invariably the foundations and

reinforcement, shuttering & cantering

etc. and support elements/liners in

tunnelling before starting the work.

Tally, invariably before starting the work,

the foundations and reinforcement,

shuttering, centring etc. and also the

support system & liners in tunnelling.

8. Shall personally see that the samplesare sent to the laboratories regularly,

obtain the results and communicate

the same to SM (QC).

Shall pursue and keep track of sending ofsamples to various laboratories and keep

record of results received.

9. Shall take the help of SM (QC)

whenever a dispute is referred.

Shall coordinate with the DGM

(Construction) and render assistance in

resolving the related issues.




CHAPTER-V

CO-ORDINATIONS

5.1 General Co-ordination and Linear Responsibility Chart

It is essential that relationship between all the groups and between individuals in t

QC group is straight forward from functional point of view and clearly spelt out. Besides tduties of field engineers detailed in chapter IV, this chapter refers to the allocation

responsibilities in relation to tasks, rights & duties and comprehensive coverage

contractual specifications and job description.

It is prudent to spell out this inter-relationship in the form of a Linear Responsibi

Chart (LRC).

A typical LRC is depicted as under: -

Sr.

No.

Task Construction

Group

QA/QC

Group

Contrac

1. Identify activities affecting quality Δ Δ 2. Organize QA/QC programme ¥ ℗ ¥

3. Approve sources / suppliers of materials ℗ ¥ ¥

4. Procure materials for the project ℗

5. Procure other materials ℗

6. Inspection & testing of materials on receipt Δ Δ

7. Testing of materials ℗

8. Accept/Reject materials ℗ ¥

9. Arrange construction plant & machinery ℗

10. Arrange construction personnel ℗

11. Geological Mapping ℗ ¥12. Installation of rock supports Δ ℗

13. Fixation of level plates ℗ ¥

14. Clearance of surface preparation for placement ℗ ¥

15. Clearance of concrete for ready placement ℗ ¥

16. Carry out construction activities ℗

17. Supervise workmanship Δ Δ

18. Inspect work in progress Δ Δ

19. Identify quality deficiencies and initiate solutions ℗

20. Causing construction unit to stop work in

progress if not of quality and to restart work

Δ Δ

21. Carry out all tests during and after construction Δ ℗ 22. Monitor & evaluate quality trends ℗

23. Investigate failures ¥ ℗

24. Accept completed work as to quality ℗ ¥

Legends: -

Primary Responsibility - ℗, Joint Responsibility – Δ, Consultative Responsibility - ¥




The construction and quality control departments must act in tandem to achieve good

quality of the finished product and construction of the project components as per the

contract specifications.

Construction department should make it a point to inform the quality control unit, the

date of starting of any construction activity well in advance, to enable the quality

control engineers to schedule their work plan and attend to a particular work on a

particular date. In turn, the quality control engineers should schedule their programmeso as to attend to the work on the dates required by the construction engineers and

ensure that the progress of work is not hampered.

5.2 Defects & Deficiencies

The mistakes, defects & deficiencies noticed should be corrected forthwith without

undue loss of time. This calls for elaborate mechanism of site observations, reporting

and communication. Quality problems and appropriate solutions shall be identified by

the QA/QC group during the course of inspection and shall be brought to the notice of

the construction group there and then.

It is the primary responsibility of the quality QC/QA group to inform/ draw the

attention of the construction group whenever they notice defective work for itsrectification/appropriate action. The construction group shall convey the resultant

instructions to the contractor to attend to the rectification work immediately and

maintain proper specifications as pointed out by the QC/QA group.

5.3 Test checks & sub-standard work

Quality Control department will monitor that all the tests required as per contract

specifications/ IS Codes are carried out in various laboratories. They will also test

check to the extent of minimum 10% of the required tests [or as decided by GM/DGM

(QC) and co-relate with the other tests conducted in different laboratories.

All observations regarding sub-standard or below specification work will be duly

recorded by the quality control inspecting officer in the Inspection books kept at site.

Such substandard or below specification work should be got stopped/dismantled

immediately by the execution unit. The defects pointed out by the quality control unit

will be communicated to the execution unit for compliance immediately. The

compliance report should be sent by execution unit within ten days to the QC unit.

The Operations of the quality control engineers shall not interfere in any way, with the

executive powers vested with the construction engineers. They will also in no way

diminish the responsibility of the construction engineers who are primarily

responsible for the quality of execution and to carry out the works as per the technical

specifications. The quality control engineers shall only conduct random checks of input

materials, machinery & equipment, excavation support system, mixing time, placementof concrete, vibrations etc. It is the primary responsibility of the construction

engineers to ensure adequate supervision of execution all the time.

5.4 Difference of opinion

The difference of opinion, if any, between quality control engineers and construction

engineers 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




related feature/aspect, the design unit should be duly consulted and the advice giv

by the designer should be considered favourably.

In case of difference of opinion between In-charge of construction and, (QC), it wobe referred to GM (construction) who would discuss the matter with GM (QC) asettle the issue.

In case there is a difference of opinion at GM level, the matter would be referred

Director (Civil) whose decision shall be final and binding. The construction and quality control departments shall keep a regular liaison w

the geologist and geotechnical expert in respect of all geotechnical aspects and entheir geological/geotechnical inputs on foundations of diversion structures includdams & barrages; deformations & stresses in tunnellicontact/consolidation/curtain grouting; rock/excavation slopes (stability of slope

protection measures; permeability/water loss tests, pattern of seepages etc. Tadvice rendered by the geologist/geotechnical expert should be discussed with designers and duly respected.




CHAPTER - VI

QUALITY ASSURANCE AND INTERNAL QUALITY AUDIT

6.1 Quality Assurance records

All planned and systematic strategies and actions necessary to generate adequate

confidence that the inputs and the output product will satisfy the given requirements ofquality and that all the components of the project will perform satisfactorily during life

period of service, the quality checks including safety and construction control measures as

adopted and as analyzed during construction is a record which speaks of “QualityAssurance”. It comprises the planning aspects and policies, education and training,standards and specifications, contracts and agreements, and quality control procedures.

Quality assurance is to assume that the materials as per standards and as per the

requirements have gone into the production of concrete, earth, support system and other

engineering works besides the design and construction techniques adopted. Thus the

quality assurance is achieved by evaluating the quality checks made during construction

and compared with post construction tests performed.

6.2 Quality Audit

Quality Audit is a systematic and independent examination to determine whether quality

activities and related results comply with the planned arrangements and whether these

arrangements are implemented effectively and are suitable to achieve the objectives.

Quality Audit is considered to be an effective management tool to promote good quality

construction and workmanship. The main reason for quality audit is the extended span of

control faced by the project authorities wherein, QC/QA is one amongst many activities

and the operations are conducted from widespread locations.

There is also an apprehension that under the pressures for achieving the physical

progress, QC/QA may be assigned a lower priority and it may get relegated to an

operational level rather than remaining as a management control service.

The solution to this problem lies in providing a quality auditing service on an internal

basis.

6.3Internal Quality Audit

6.3.1 Objectives

Internal audit is an independent and impartial appraisal function to examine and evaluate

QC/QA activity and report to the management.

Internal audit acts as a management control and it functions by measuring & evaluating

effectiveness of various controls suggested under QC/QA system.

The objective of quality auditing is to assist the management in the effective discharge of

the responsibilities by furnishing them with the analyses, appraisals, recommendations

and suggestions concerning the activities reviewed.

The quality audit group should have a positive approach along the line of reasoning that

may be characterized as follows: -

If the QC/QA system is defined to achieve a required quality and if the system is

actually operating as planned, then the final results should be fully acceptable.




The quality auditors’ examination should therefore be oriented towards determining tefficacy of the intended QC/QA system ascertaining whether the system is actua

functioning as planned and as specified and then evaluating the reliability and accuracy

final results to merit a favourable opinion.

The quality auditors’ concern should go much beyond just the verification of records a

procedures available with the QC/QA department. Full understanding of the operatio

under review would further improve the quality of project implementation.6.3.2 Scope & Functions

The scope of quality audit group activity should be primarily concerned with evaluati

compliance and verification.

1.

Evaluation

The “service to management” concept of quality auditing ultimately extends to tmaking of recommendations to improve the operations and strengthen controls, based on t

evaluations that have already been made.

The evaluations/recommendations may generally cover the following aspects: -

i)

Evaluation of testing and inspection efficiency in respect of matters such as: -

Effectiveness of procedures. Operational efficiency of plant and equipment. Adequacy of personnel.

Program of records. Retention & destruction of documents.

ii)

Evaluation of internal control as to how well the QC/QA system provides for: -

Information that is adequate and accurate.

Effectiveness of communication and feed back of management decisions to

operational level. Control over all phases of operations.

iii)

Evaluation of overall performance of various labs from the stand point of: -

Plan of inter-laboratory organization. Procedures being followed.

Performance of individual laboratories.

In some cases, the technical matters encountered by the quality audit group may

outside their area of competence and in such cases, assistance from other intern

departments or even from outside the organization may be obtained.

2.

Compliance

Procedures or controls are of no significance unless they are carefully followed in pract

Quality Audit will endeavor to ascertain whether the planned program is actually be

carried out in practice.

The technique of ascertaining the above aspect may vary from enquiry & observation

examination of the records/reports and proofs of completed work to establish that t

work has been properly performed.




3.

Verification

The activities related to verification involve scrutiny of test/inspection reports and

particularly the management reports prepared from these records. This would include

comparison of report, figures and source information, proof of entries in the source

records etc.

While carrying out the quality audit, the audit group should review the activities of each

laboratory and those of the inspection group in order to determine whether the functionsand responsibilities assigned to each laboratory/inspection department are being

performed in a satisfactory manner, specifically to ensure that: -

Each laboratory/inspection department is provided with procedures to ensure, if followed, satisfactory quality.

The personnel deployed in the laboratory/inspection group are adequate in terms ofnumber, relevant qualification and experience.

The testing and inspection personnel have adequate and consistent understanding of the

procedures.

The testing and inspection carried out are adequate as to timeliness and as to quality.

Adequate corrective actions are being taken to prevent the recurrent use of defectivematerials or workmanship.

The records and reports of testing and inspection, maintained at each focal level, areaccurate and complete.

The communication at each level, starting from operational level to management leveland vice-versa, are received in time, and expeditiously dealt with to ensure prompt

feedback on the management decision for effective control.

Management has provided adequate controls which when operated effectively will ensurehigh quality and whether these controls are operating in a satisfactory manner.

Approvals in writing are being obtained on all the actions and records/reports arechecked by the supervising officials.

Corrective actions are being implemented in the shortest time period.

6.3.3 Audit Sampling

Auditing of each and every record is not only unwarranted from economic point of view

but is also unnecessary from statistical point of view.

A fairly good approximation of random selection of records as a sampling unit for auditing

can be obtained by the use of systematic sampling i.e. Interval selection method instead of

random selection.

The Interval selection method involves selecting sampling units using a fixed interval

between selections, the first interval having a random start. In this method, every nth

report, as a sampling unit in a series, is selected where n is determined by dividing the

total number of reports in the population by the number of reports to be included in the

sample audit.

6.4 Internal Quality Audit Group - Desired Standards & Formation of the group

For effectiveness of the quality audit, independence is essential which can be obtained

primarily through organizational status and objectivity.




The functional head of the quality auditing group should be responsible to the t

management whose authority is assured both in terms of coverage and adequ

considerations of findings and recommendations including action on the same.

The following desired standards are to be kept in view while forming the auditing group

Independence of personnel should be maintained at all organizational levels.

Personnel assigned to this activity should have appropriate degree of technical train proficiency. Personnel must be imaginative and broadly trained to comprehend the bro

constitution of project activities and its problems. Adequate opportunities for consultation should be made available in resolving questi

that arise relating to procedures, compliance requirements etc. To ensure compliance with the standards of quality, the auditing activity at all lev

should be supervised and controlled by head of the auditing group.

For HPPCL Projects, Director (Civil), HPPCL shall constitute the Quality Audit group

for undertaking the internal quality audit of the works. The group(s) will comprise of

least three members of the level of GM and will be headed by senior most GM in the group. Gof a particular Project shall not be the member of the group for that Project. The group can

constituted from HoPs/GMs of various Projects of HPPCL, Civil Design, Civil Contrac

Corporate Planning, Corporate Monitoring, QC etc.

Besides the scope & functions given under 6.3.2 above, the Quality Audit group shall a

focus on:-

Visual Inspection of works completed or under progress; perusal of video graph photographic records.

Perusal of Quality Control & Quality Assurance (QC/QA) documentation; and all t

records including OK Cards and registers. Contractor’s workforce and construction equipment deployed at works and assessing

adequacy thereof in respect of the quality related aspects; whether the contractordeploying the key/critical equipments, as listed in the contract documents and required.

Any other aspect relating to quality and safety which requires immediate attentionHPPCL management.

6.5 Program of Quality Audit

To make the program of quality audit effective it should be properly plann

implemented and updated on regular basis. The audit should culminate in a form of comprehensive report which can be a “short ter

and a “long term” report. The short term report should be made available to the management once in a quar

whereas, the long term report should be prepared on annual basis.

Each report should bear date of the audit and the signatures of the audit group.




I.

Short term report:

The short term report should include the following points in the recommendations

based on the audit study;

Establish credibility of the Test and Inspection reports. Ascertain the standard of testing.

Delinquencies: Pending tests, delayed reporting, delayed communication, absence ofcertification or authorization. Review changes since last audit study.

Ascertain receipt of feedbacks from management on non-compliance reports. Tie-in supporting data with reports submitted to the management.

Determine that all decisions on non-compliance have been taken. Establish efficient functioning of laboratory equipment.

Ascertain implementation of management decisions. Establish the existence of permanent documentation and retrieval system.

Determine that the procedural requirements have been strictly adhered to by each andevery focal official.

The above list cannot be said to be completely comprehensive but, may be used only as

a model for preparation of a work plan by the audit group suiting specific projects.

II.

Long term report:

The long term report should contain specific recommendations on the following

aspects to what has been brought out in the short term report;

Effective QC/QA organization structure

Delegation of responsibilities Internal reporting

Management controls

Safeguard against delinquencies Human resource development

Efficiency of equipment

Inter-laboratory organization set-up Trend in overall quality of construction

While carrying out the audit exercise, the audit group should obtain sufficient and

competent evidential matter through the following processes: -

Inspection/Examination: To substantiate the authenticity of various recorded figuresand entries, evidences should be gathered by referring to all records and documents

pertaining to testing. Confirmation: The process of confirmation should be carried out wherever thesupporting evidence can be obtained from elsewhere rather than by referring to items ofevidence that are readily available.

Observation: The technique of observation is expected to be made use of whileascertaining compliance with the prescribed departmental procedures. For example, ifthe procedure for calibration of equipment is prescribed as once in six months, the audit

group should observe whether this was being done by the testing laboratory personnel.




Verification: In larger sense, all the activities of the quality audit group are relatedverification and formulation of an opinion. However, in a more limited sense, it may reto the verification of calculations, recording and transferring of data.

Enquiry : In a course of examination, it may be necessary to obtain much of information that is needed about the person who is likely to be able to supply trequired information. By carefully phrased questions, the audit group will be ableascertain whether or not the individual is properly carrying out the assignresponsibilities.

The report should contain an abstract of findings and observation including opini

and recommendations. It should be duly substantiated by supporting explanations a

documents which should also form a part of the report.

The report will be sent to all the concerned officials of QC/QA as well as constructi

department for compliance.




CHAPTER - VII

O.K. CARDS

7.1 OK Card System

The OK Cards contain important entries/information relating to execution at all stages

of work and are liable to be referred/perused at a later stage as well, particularly during theInternal Quality Audit of works.

The OK Cards shall be maintained in duplicate in two colours. The green coloured card

shall form a part of the record of QC unit and the red or pink coloured card remains in the

custody of construction wing. The OK Cards relating to any particular work shall be put in a

round shaped tin box and placed right at the construction site office. The exterior of the tin

box shall be painted red.

Senior officers shall also check the OK Cards during their field inspections to ensure

that these are being maintained properly and genuinely filled.

An OK Card is a condensed form of specifications and an essential requirement forachieving 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 in the OK Cards.

For various stages of construction activities where laboratory tests or checks with

reference to drawings and specifications are required from quality control unit, OK card

system shall be followed. The OK cards should be made available on the site in regular

manner. Approval of the component of work in progress at the times of inspection should be

recorded by the inspecting officer.

7.2 Filling of OK Card

The OK Card consists of two parts for each work. The first part covers the initial

preparedness for the work and indicates pre-requisites whereas the second part covers the

daily performance of activities based on pre-requisites and also granting

permission/authorization/ okay by the construction as well as Quality Control units to

perform the job.

The first column of the OK Card is to be filled by the construction agency (contractor)

by preparing each feature including the location and type of work and making it ready for

inspection by the project construction engineer who okays through his signatures and then

puts up to the QC engineer for the final OK. If QC engineer is not available at site then OK given

by construction engineer will be treated as final. Should anything otherwise is found, the OKcard shall not be signed by him and ask the construction agency should be asked for necessary

rectification.

Subsequently, OK card should refer to the defects removed, if pointed out previously in

the OK card with counter reference to the previous check and should be signed ‘Okayed’.

It must be borne in mind that work cannot be held up unduly for disposal of OK card.

E1 to E5 level engineers of Quality Control & construction will be the okaying authority.




Random checks by supervising officers should be recorded on OK cards at site. Wee

report of OK cards maintained by construction unit should be submitted to QC unit to moni

and ensure that adequate check is being maintained by the construction unit. Confirmati

regarding rectification of defects is to be obtained from QC unit before making payment.

After processing through various levels and entering observations and rectificatio

the OK card will be closed at the time of taking measurements for releasing payment to t

contractor.

Photocopy of the OK card (pink/red) will be kept at site and original copy will

attached with the bill and will be kept on record by the disbursement office while mak

payments to the contractor.

Photo copy of OK card (Green) of Quality Control will also be enclosed with the bil

kept on record with the bill by the payment disbursement office. However OK card of Qual

Control will not be closed till the work is finalized and will be kept on record by the Qual

Control unit after the rectification is completed by the construction wing and final comme

are recorded by both i.e. construction as well as QC engineer.

7.3 Specimen of OK Card

O. K. Card specimens for Civil and HM Works are appended in the section “O. K. Car

– Specimen (Civil & HM Works)” for: -

Civil Works: -

Excavation Underground Structures-Concrete Lini

Placement of Concrete for Dam/Open Works

Placement Report Reinforcement Inspection Checklist Plain & Reinforced Cement Concrete w Compressive Strength of Concrete Rock Bolt Test Result

Sieve Analysis for Sand/Fine Aggregate (IS:383)

Calibration of Batching Plant Safety Checklist

Hydro Mechanical Works: -

1 & 2 Stage Embedments Authorization Powers

DT Gates

DT Gates 2nd Stage Erection of Gates Gantry Crane Hoist

Hydraulic Hoist Piping

Legends Receipt & Storage Storage & Receipt

Storage & Receipt

The formats of OK Card are indicative one and may be formulated at Project (s)

consultation with GM (Designs), if needed.




CHAPTER - VIII

TESTS TO BE PERFORMED ON CONSTRUCTION MATERIALS

8.1 General

Satisfactory quality control system for construction of components and structures of a

hydro power project depends largely on quality of construction inputs i.e. cement, aggregates,water & ice, admixtures, steel, puzzolanas etc. besides performance of plant and machinery,

and the workmanship employed.

Having controlled the inputs to the extent possible, it is necessary to evaluate the

quality of output i.e. the concrete shotcrete etc. in terms of various identified tests and its

placement.

Thus in the overall quality assurance system, testing of inputs as well as the outputs is

essential.

8.2 Tests to be performed

The tests on the construction materials and frequency of testing should be performed

as per relevant Indian Standard codes (with latest editions) and/or as specified in the

technical specifications, and shall comply with the limits and tolerances given therein.

The IS codes mentioned below should be cross linked and referred along with other

related IS codes and standards.

Material Test

Cement

IS: 269-1989 IS:8112

IS: 4032 - 1985 IS:12269IS: 455 - 1989

IS: 1489-1976

a) Chemical

i) Sio2, Al203, Fe203, Cao, MgO, Cao, SO3,

Insoluble residue & Loss on ignition.ii) Alkalis & Chloride contents

iii)

Free lime

IS:4031- 1988 b) Physical

i)

Specific gravity

ii) Fineness of grinding

iii) Soundness (boiling test)

iv)

Compressive strength after 2,7,28 days

v) Bending tensile strength after 2,7,28 days

vi)

Consistency

vii)

Initial and final setting timeviii)

Heat of hydration/Drying shrinkage

Water

IS: 3025- 1987

(Part I, XXIV, XXVII, XXXII)

IS: 516 – 1959, IS: 1199- 1999

i)

Cl, S04, Organic & Inorganic Solids, pH,

Alkalinity/Acidity

ii)

Setting time of mortar

iii)

Relative strength of concrete

iv)

Soil particles conveyed




Fine Aggregate

IS: 383 - 1970

IS: 2386 – 1963

(Part I to VIII)

i)

Grading & Fineness Modulus

ii) Test for organic impurities, dust, silt & cl

particles

iii)

Decantation test for silt

iv) Specific gravity & water Absorption

v)

Unit weight and bulkage

Coarse Aggregates

IS: 2386 – 1990

(Part I to VIII)

i)

Gradingii) Flakiness index

iii)

Elongation Index

iv) Deleterious materials

v)

Specific gravity

vi) Bulk Density & grain shape

vii)

Moisture content

viii) Absorption value

Mechanical tests

i) Aggregate crushing value

ii)

Impact Value

iii) Abrasion Value

iv)

Alkali aggregate reactivity

v)

Soundness

vi)

Petrographic examination

Embankment materials

(Latest Editions)

IS: 2720 (Part II, IV, XII)-1975

(Part V, VII, VIII) – 1970

(Part XV) – 1965

(Part XVII, XXIX) – 1966(Part VI, XVIII)-1972

(Part III)-1964

(Part XXVIII)-1974

(Part XXXIII)-1971

i) Proctor’s compaction and density tests

ii)

Atterberg’s Limits

iii) Permeability

iv)

Shear Tests

v) Specific gravity

vi)

Abrasionvii) Other soil mechanic tests as required.

Concrete

IS: 10262-1982

IS: 456-2000

IS: 516-1999

IS: 1199

IS: 5816: 1999

IS:13311-1992 (Part 1&2)

a) Fresh Concrete

i) Air Contents

ii)

Vibration

iii) Temperature measurement

iv)

Mix proportions

v) Water cement ratio

vi)

Unit weightvii)

Yield

b) Workability test

i)

Slump (consistency) Test

ii) Compaction Factor test




c) Hardened Concrete

i) Compressive strength

ii)

Core testing

iii)

Special Tests

Non-destructive tests

Ultrasonic pulse velocity: Standard test

method – ASTM C597-83/BS 4408, Part

5:1974

Rebound hammer test: Standard test method

for rebound number of hardened concrete-

C805/C805M-08/BS 4408, Part 4:1971

Shotcrete (Including SFRS)

IS: 9012 – 1978 (Reaffirmed 1992)

IS:15026 - 2002

i) Aggregate gradation

ii)

Suitability test for Accelerating admixtures

and additives.

iii) In-situ compressive strength

iv)

Setting timesv) Rebound (Total & Final Rebound)

vi)

Flexural strength

vii) Bond strength (between layers & with rock)

viii)

Toughness

ix) Tolerance of length, dia and aspect ratio of

fibers

x)

Fiber tensile strength

xi)

Physical and chemical requirements of

additives such as microsilica etc.

Admixtures

IS: 9103 - 1990

IS: 516 - 1999

IS: 8142 - 1992

IS: 1199- 1999

i)

Bleedingii) Relative Strength

iii)

Setting Time

iv) Relative water content

v)

Relative length change

Drilling and grouting

IS: 5878 - 1972 (Part 7)

IS: 6066 -1994

IS: 12584-1989

i)

Specific gravity

ii) Compressive Strength, contents above 70

micron & setting times of cement

iii) Unit weight of grout Mixtures

iv)

Flow properties of grout

v)

Plastic viscosity, yield strength & apparent

viscosity of grout

vi)

Standard classification & Quality tests on

cement, bentonite & additives etc. for

pressure grouting

vii) Water pressure test in grout holes




Masonry

IS: 1123-1990

IS: 1124-1990

IS: 1127-1993

IS: 1129-1993

IS: 1597-1996 (Part I)

IS: 2116-1998IS: 2250-1990

i)

Gradation of Sand

ii) Slump Test

iii)

Compressive strength of mortar

iv)

Tests for stones & cement blocks

Water absorption

Specific gravity

Porosity

Weathering of natural building Stone

Mild steel for reinforcement / Steel

lining / Steel plates

IS:432-1995(Part I)

IS:1786-1990

IS:2062-1993

IS:9595-1996

IS:228-1987

IS:1599-1991

i)

Welding tests

ii) Impact strength

iii)

Tension test

iv) Ultrasonic tests

v)

Seam tests

8.3 Sampling for testing of materials:

Sampling is an important link in the whole chain of construction leading to decisio

contractual relations, safety and economy-related aspects.

Tests on samples are representative of the quality of the actual work which t

samples represent and therefore judicious care is required in obtaining

representative samples.

A pre-arranged sampling plan is required to be formulated stipulating the location a

procedure for obtaining samples of materials for testing purposes.

Standard procedures for drawing samples of cement, concrete, puzzolanas, aggrega

and admixtures are described in the following respective Indian standards: -

IS: 3535-1986 IS: 456-2000 IS: 1199-1959IS: 3812-1981 IS: 2430-1969 IS: 9103-1979

Sampling of cement.

A.

Level of variability [Standard deviation or coefficient of variability]

Cement will be received at site from selected cement plants indicating the level

variability expected in the characteristics of cement produced, including compress

strength at different ages, based on the laboratory data in the plants and for the frequency

testing that is usually followed.

The appropriate sampling plan as well as basis of acceptance of cement should

worked out as under: -

By inter laboratory testing it should be established that there is no statistically significdifference between the test results of identical samples carried out at the site laboratoand the cement plant laboratory.

If statistically significant difference does exist, then decision-making process will have

be on the basis of the results obtained in the site laboratory itself, with appropricorrections in the targets.




In the case of (ii) above, cement samples should be collected both at the cement plant aswell as the project site from the same consignment and tested by both the laboratories fora considerable time (say about 3 months) and arrive at the limit of variability i.e.standard deviation or coefficient of variation.

For the purpose of acceptance consideration, limit of variability can then be based on thevalue of coefficient of variation as obtained in tests in the project laboratories as at (iii)

above or 8% whichever is lower. The test results should be compared with suitable control charts on the basis of the target

average strength of cement and the statistical parameters of variability obtained.

B. Control Charts for cement and concrete strengths [Refer Chapter XIV- Monitoring

Through Control Charts].




CHAPTER - IX

LIST OF EQUIPMENT FOR AND CONCRETE TESTING

Sr.

No.

TEST EQUIPMENT*

1. CEMENT

a) Chemicali) Alkalis.

ii) Minor, major oxides.

iii) Chloride content.

iv) General.

b) Physical

i) Fineness.

ii) Soundness.

iii) Consistency and Initial & Final

setting times.

iv) Compressive Strength.

v) Heat of Hydration.

vi) Drying Shrinkage.

vii) General.

Flame Photometer.

For measurement of concentration

alkaline elements.

Calorimeter to determine heat of hydrat

& setting behaviour.

Spectrophotometer.

Potentiometer, Silver Electrode, Calom

Reference Electrode, Salt bridge.

Water Distillation still, Oven, Hot pla

Balance (Accuracy 0.0002 g), Mu

Furnace (up to 1200 deg. C). PlatinuCrucibles, conductivity Bridge, pH Met

Sample divider for powders, physi

balance (Cap. 150 gm).

Blaine apparatus, stop watch.

Le Chatelier mould (IS: 266), Hot water b

Autoclave, Length comparator (IS: 4031).

Vicat needle apparatus (IS: 5513), moul

setting time needles.

Compression Testing Machine (50 tonn

Vibrating Machine, Moulds (50 sq.cm areaCalorimeter, Beckmann Thermometer.

Length Comparator, Flow Table.

Stop Watch, Timer, Temperature Control

Oven, Humidity Chamber Incubat

Physical Balance (Acc. 0.001g), Balan

(cap. 5 kg, Acc. 1g), Control Room (Tem

controlled curing tanks), Set of standa

sieves lid & receiver.

2. AGGREGATES & CONCRETE

i) Crushing value.

ii) Impact value.

iii) Abrasion value.

iv) Alkali Aggregate Reactivity.

v) Flakiness/Elongation indices.

Crushing apparatus.

Aggregate Impact test machine.

Los Angles abrasion test machine.

Reaction Containers.

Apparatus for measuring Flakiness a

Elongation Indices.




vi) Unit Weight Containers.

vii) Sampling (Sand).

viii)Specific Gravity & Absorption.

ix) General.

Minimum Capacity of measures.

Max. size (mm) Capacity of measure

(dm3)

2.5 6

37.5 11

50 14

75 (1cft) 28114 71

152 99

Reffler Sample Divider.

Pycnometer.

Electric Drier, Hot plates, Set of standard

sieves lid and receiver, Balance 10kg acc.

1g), 100kg (acc. 0.001Kg), 200 kg. (acc. 0.5

Kg.), Scoop, Enamel trays, showel,

Compression testing machine (200tonne),

Crusher and Ball mill, providing rigs 1,

2,25,50,100 tonne.3. CONCRETE

a) Fresh Concrete

i) Air Content.

ii) Vibrations.

iii) Temperature measurement.

iv) Mix proportions.

b) Workability Tests:

i) Slump Test (Consistency).

ii) Compaction factor test.

iii) Vee Bee Test.

c) Hardened concrete

i) Compression, Flexural, Tension

Bending & Brineel’s Hardnesstests tension.

ii) Capping of cylinders.

iii) Testing of curing compounds.

d) Special Tests

i) Microscopy.

ii) Non-destructive.

iii) Core Testing.

ir meter.

nternal Vibrator, table vibrator.

etallic Temperature sensor.

aboratory concrete mixer & equipment as

er IS: 1199 for determination of constituents.

lump cone & Tamping rod apparatus.

ompaction Factor apparatus, Concrete

orkability meter.ee Bee Consistometer.

niversal Testing Machine with accessories

(Cap. 100 tonne).

apping moulds.

eflectance Meter.

ptical Microscope, Grinding and Polishing

quipment.

ltrasonic Pulse Velocity, Rebound Hammer,

over meter.

ore Drilling, Rock Cutting Machine, Thermal

onductivity Apparatus, Permeability

pparatus, Creep Test Apparatus.

* Equipment list is not exhaustive, refer relevant IS Codes.




CHAPTER - X

IMPORTANT SPECIFICATIONS AND CONSTRUCTION CONTROL

10.1 UNDERGROUND EXCAVATION AND SUPPORT SYSTEM:

IS Codes: - 4410, 4880 (Part 1 to 7), 5878 (Part I, II, III, 4, 5 & 7), 10386 (Part I, II, 3

5, 6, 7, 8 & 10), 6065, 7422, 7974, 10290, 2062, 9595, 814, 15026.10.1.1General

Underground excavation includes all excavations performed by tunneling metho

The general dimensions, arrangements and details of typical sections of tunnels, sha

caverns etc. and the support elements should adhere strictly to the specifications a

drawings.

During construction, tunnels and other underground structures shall be drain

lighted and ventilated as specified. Safety of human beings working underground is of utmo

importance besides safety of installations, equipment and materials.

The excavation shall conform to specified widths, lengths and depths, and carried o

in sections strictly as shown on the drawings.

10.1.2Care during underground construction

All necessary safety measures have to be adopted to protect the persons engaged

underground works from cave-ins / rock falls, harmful gases or vapors, fortuitous explosio

intoxications, electric discharges, floods, fires and all other accidents of probable occurrenc

The caring measures are to be fulfilled with cautious approach by all concerned

Constructors, Supervisors, Quality assurors as well as Planners & Designers.

The following aspects need extra care during construction of underground works;

A.

Drilling & blasting operationsThe excavation shall conform to specified widths, lengths and depths, and carried o

in sections strictly as shown on the drawings.

All underground blasting should utilize “smooth-blasting” techniques by usappropriate number of micro-milli and half-second delay detonators

Specific care should be taken with regard to the following: -

Minimum loosening at the excavation surface and tunnel walls.

Least possible vibrations to tunnel supports, lining, neighbouring tunnels and surrounding mass.

Controlled pressure wave to eliminate adverse effects on form work, fresh concrebuildings above ground, neighbouring tunnels etc.

Least possible over breaks and within prescribed lines.

Minimum rock falls in fault zones.

Unstable or loose material appearing during excavation, due to improper blasting or dto any other operation, which may be dangerous for the personnel or work, to removed/repaired immediately.

Excess excavated space is filled with such material and in such a manner, as specified.




Ensuring workmanlike driving and supporting operations by deployment of experiencedsupervisory and quality control staff besides engaging skilled and licensed expert tunnelminers.

Use of explosives including their transport & storage should be strictly in accordance withthe regulations in force.

Blasting to be done at specified times with sufficient notices, adequate forewarnings &

barriers.

Ensure that all charges loaded have been detonated and that no more-delay explosions ormisfires are expected.

Rail tracks, ventilation tubes and supply lines are safely grounded to prevent danger to persons from lightning and to avoid possibility of explosions from loaded or unloadedcharges.

Charges be prepared outside the tunnels and with extra precautions in the case of electric

detonators viz protection with insulating caps, check by a galvanometer or ohmmeter,lightning detectors etc.

The net depth of the hole should be checked before placing the charge.

Records of all blasting events including location, time, charge, type of explosives,

detonator type and arrangement, purpose, etc. on prescribed forms should be properlykept for reference/quantity of explosives and no. of detonators used in blast.

B.

Ventilation

To provide breathing air conditions in the tunnels not detrimental to the health of

workers, a temporary ventilation system shall be installed, maintained and operated

following the excavation works.

The ventilation is to be operated during excavation as well as concreting phase in

accordance with the requirements of the technical details but shall not be removed thereafter

without written permission of the safety/QC engineers.

C.

Lighting and Power

All power and lighting wires should be installed and maintained in optimal conditions

of insulation and safety.

Power and lighting cables should be installed on one side of the tunnel and the

detonator wires on the opposite side and sufficiently distant from the telephone or

communication wires.

The temporary lighting shall remain in commission until tunnel construction is

complete.

Tunnel lighting supply underground shall be independent of the power supply for anytunnelling machines, plant, equipment or tools.

All wiring to be securely fixed clear of any moving plant, man access, source of heat or

other likely damage.

Lighting in running tunnels shall generally consist of not less than one 60-watt lamp at

6m centres or equivalent with proportionate increase in enlargements.




D.

Fire Fighting

The Fire fighting equipment to be provided in tunnelling shall be in compliance w

internationally recognized standards.

An alarm procedure shall be developed in the event of any emergency as well as

vulnerable areas in the tunnel and should be provided with individual fire points.

Gas cylinders should not be stored inside the tunnel and must be removed after use.

Burning and welding underground be kept to a minimum. Propane in preference

acetylene should be used. Sand buckets and fire extinguishers should be immediat

available when cut-welding is carried out.

Storage of combustible materials shall be kept only to the extent that are required

immediate or emergency use and the waste must be removed at the end of each shift.

A Site fire-squad should be designated and trained to use apparatus, monitor

readiness, check and report on unsafe practices.

Access to the site for emergency vehicles should be maintained at all times.

E. Drainage

Adequate arrangements for drainage of water escapes and in-rushes should be made

underground works in terms of pumps, pipes and adequate capacity of dewatering etc. T

water has to be collected, channelled and piped out of the tunnel.

Prior to shotcreting work, water running over the rock surface has be collected

drain pipes and channel formed by rapid hardening mortar.

Severe influx of water from faults or fracture zones should be reduced by grouting.

The technique adopted for control of water should ensure stability of the tunn

excavated face during and after construction. It shall also be ensured that no washing-out

fine materials occurs which may lead to progressive settlement or loss of stability of tunnel

F. Communication & Access

A robust two-way communication system shall be installed between each worki

face, each fire point and other important facilities and maintained in efficient manner in

the underground works.

Safe access to all the underground works should be provided through walkways hava minimum clear space of 1800 mm high and 750 mm wide with a walking surface of not le

than 400 mm wide.

Water should not be allowed to stand or accumulate at or above the walkway level

any point. Any spillage of spoil or other material on the walkway should be remov

immediately.




10.1.3Geological Mapping During Tunnel Excavation

Geological mapping during tunnel excavation should be carried out for each 50 meters

of completed excavation work by the constructor.

Following records of geological information as obtained during excavation should be

maintained in a comprehensive manner: -

Rock classes.

Rock formation & orientation (dip & dip direction).

Fracturing, schisosity, weathering location etc.

Size & nature of faults.

Ground water appearance.

Geological plans & sections.

Sudden & unexpected changes observed in geological conditions of rock/soil.

Videos & Photographs.

10.1.4Geotechnical Monitoring of Underground works and instrumentation

To ensure quality execution, construction control and to monitor actual behavior of

underground rock during construction, continuous monitoring of field performance relating

to tunnel excavation, support elements, linings etc. with effective geotechnical

instrumentation is essentially required.

Geotechnical instrumentation shall involve measurement of following parameters;

Deformation or displacement to monitor the behaviour of Rock mass /Soil in

underground caverns/tunnels.

Ground water pressure or Pore water pressure to monitor sub-surface water flow &seepage patterns and their effect on deformations / stress change.

Load and strain (Movement of compression & extensions) in the support elements. Temperature variation & its effect on deformation / stress change in rock during

supporting excavations & tunnel lining.

Interpretation of data collected from instrumentations.

The instruments selected for geotechnical monitoring should fulfil the following major

selection criteria: -

Easy accessibility in all U/G cavities.

Reliability.

Simplicity.

Durability in harsh installed environments like dust, dirt, mud, high humidity, gases, fumes, flowing or standing water, flyrocks, shocks, temperature extremes, shearingdeformation corrosive actions etc.

High accuracy.

Minimum interference to construction.

Availability of spares and readout units.

High resolution, to be able to be interfaced to remotely placed control room.




Full scale test section should be instrumented in tunnelling to establish sta

excavation.

The geotechnical instrumentation shall essentially include interpretation and analy

of measurement data by the experts.

Instrumentation data observed should be interpreted and analyzed immediately a

implemented for taking corrective and preventive measures & also for refinements in ongoing construction techniques / methodologies.

For U/G works, generally the following geotechnical instruments shall be required: -

Bore Hole Extensometers.

Tape Extensometers.

Piezometers.

Load Cells.

Concrete & Shotcrete Stress Cells.

Strain meters.

Stress meters.

Thermometers.

Read out Units & Automatic Data Acquisition System.

The Quality Assurance engineers should frequently visit the locations of install

geotechnical instruments to ensure that the instruments are adequately maintain

and are being used for the purpose for which they have been installed in t

underground works.

10.1.5Shotcreting (plain/Reinforced)

Quality Requirements: -

Shotcrete (dry or wet) is an intimate mixture of Portland cement, aggregates, wa

and additives (if applicable), shot into place by means of compressed air through a spr

nozzle. It is used either as an arch with load bearing functions in a tunnel cross-section or a

sealing in tunnel lining. All surfaces shall be wet, clean and free from rebound at the time

application of shotcrete.

If shotcrete is properly proportioned, mixed, placed and cured, it forms a very ha

high strength concrete.

Shotcrete shall be uniform, compact, monolithic texture and free of cracks in the ent

tunnel cross-section.

All steel parts such as wire, reinforcing steel, mesh, arched steel rib supports e

remaining in the shotcrete shall be neatly covered throughout their entire extent by at leas

cm of shotcrete.

Any adherent rebound and/or loose or clogged material from previous shotcret

shall carefully be removed before shotcreting.




Mix Design: -

To meet the requirements of shotcrete for strength development and final strength, the

mix shall be designed by laboratory tests and field trials taking into consideration the

following factors: -

Cement content: - Quantity of cement shall not be less than 350 kg/cum dry mix for

dry shotcrete process. For wet process, the minimum cement content shall complywith the standard mix of class M: 25.

Water-cement ratio: - For dry process, the water content shall be controlled by the

nozzle man to suit the conditions of the shotcreting surface and location of application.

For wet process, field trials shall be carried out to determine and establish the

suitability of water/cement ratio. However the w/c ratio shall be between 0.35 to 0.50.

Setting and strength development: - Accelerating admixtures shall be used in a

suitable dosage rate (determined by suitability/compatibility tests) to meet the

requirements for setting and strength development of shotcrete applied. The uniaxial

compressive tests shall be done as per concrete specifications. The strength

development due to suitability tests must exceed the specified in-situ strength by afactor 1/0.85 (1.18). The 28-day-strength of shotcrete shall be minimum 25N/mm2.

Temperature of mix: - The water temperature shall be kept at 20 (+-1) Celsius and

cement & accelerator at room temperature.

Nominal size of aggregate shall not exceed 10mm. The grain size distribution of the

coarse aggregate of 10mm nominal size shall be as under:-

Sr. No. IS Sieve designation (mm) Percentage by mass passing

1. 12.5 100

2. 10 85-100

3. 4.75 10-304. 2.36 0-10

5. 1.18 0-5

Following combined aggregate gradation curve shall be taken as guide for mix design

purposes, but may be modified, subject to the results of trial mix tests, as required under

Sections, General Requirements of this drawing.

Sr. No. IS Sieve designation (mm) Percentage by mass passing

1. 9.5 90-100

2. 4.75 73-100

3. 2.36 55-90

4. 1.18 37-72

5. 0.60 22-50

6. 0.30 11-26

7. 0.15 4-12

8. 0.075 2




10.1.6The steel fibre used in SFRS shall be produced from high tensile steel, either cold rol

or cold drawn wires. Fibres shall be dry and free from oil, grease and chlorides. T

fibres shall satisfy the following parameters:

Length of steel fibres Geometric shape 20mm-40mm (Tolerance = ±10%) Stee

fibres shall have suitably deformed profile t

ensure proper matrix of SFRS mix and t

develop better bond anchorage with no fibeballing.

Aspect ratio (length/diameter) 60-75(Tolerance = ±15%)

Fibre Tensile Strength quantity of steel

fibres

> 1000 MPa 39-150 kg/cum(subject to mi

design/field trials)

Mixing procedure adopted should be such that there is no fibre balling i.e. fibers do n

tangle together to form clumps or fibre balls.

10.1.7 Microsilica shall be added in the mix at the batching plant for facilitating the mix

and distribution of fibres to reduce fibre rebound and improve bond between ceme

matrix and fibres as also to improve adherence when the rock mass surface is wet. Tdose of silica fumes shall be 8-15 % of cement by weight subject to site trials. Sil

fumes shall have a bulk density between 500-700 kg/cum. Chemical & Physi

requirements of the Micro Silica shall be as under:

Chemical Requirements

Sr. No. Characteristic Requirement Minimum frequency of Testing or as

desired by Engineer-in-Charge.

1. SiO2*, Min 85.0 Single Lot upto 400 t

2. Moisture content*, Max 3.0 Single Lot upto 100 t

3. Loss on ignition* Max 4.0 Single Lot upto 100 t

4. Alkalies as Na2O, Percent,

Max

1.5 Single Lot upto 400 t

*Percent by mass

Physical Requirements

Sr. No. Characteristic Requirement Minimum frequency of Testing o

as desired by

Engineer-in-Charge.

1. Specific surface m2/g, Min 15 Single Lot upto 400 t

2. Oversize percent retained on 45micron IS sieve, Max.

10 Single Lot upto 100 t

3. Oversize percent retained on 45

micron IS sieve, variation from

average percent, Max.

5 Single Lot upto 100 t

4. Compressive strength 7 days As

percent of control sample, Min.

85.0 Single Lot upto 400 t




10.1.8Proportion of admixture shall vary between 2% to 7% by weight of cement or as

finalized herein after based on test results, prior to any shotcrete work.

Accelerator dosage shall be minimum, and not to exceed 5% by weight of cement

material in general. Testing of accelerator with regard to setting time and early strength gain

shall be in accordance with the following time/strength limits.

Synthetic fibera) Initial set of cement/admixture paste- 3 minutes Product features

Final set of cement/admixture paste- 12 minutes Tensile strength 400-500MPa

b) 3-hours strength of shotcrete- 0.7 N/mm2 Specific gravity 0.90-0.92

8-hour strength of shotcrete- 4.0 N/mm2 Young’s Modulus 10GPa

24-hour strength of shotcrete- 10.0 N/mm2 Melting point 150°-165°C

Ignition point >450°C

Batching, Mixing and Transportation: -

Cement and aggregates should be batched in the proportions as specified and

designed.

At the time of batching all aggregates should have been dried or drained sufficiently toresult in stable moisture content (within 7%).

Mixing of cement and aggregates should be performed mechanically. The mixing time

should not be less than 60 seconds.

Shotcrete is not to be used unless placing can be completed in 90 minutes.

The time span should be kept as short as possible, especially at seasons with high

temperatures and high humidity.

Accelerating admixtures (proportioned after testing) should be added to the dry mix

for dry process just before it enters the shotcrete machine through a dispenser or a specialdosage pump as specified.

During cold weather periods, provision should be made to maintain the setting

properties of the shotcrete by means of heating the water or aggregates or both depending on

the temperature.

During hot weather, the water content of the aggregates should be kept above 4% (for

dry process) to avoid cement loss.

Materials’ & Plant Suitability: -

Cement shall be Portland cement and its material uniformity should be guaranteed.(Refer Chapter XII)

Where chemically aggressive ground water occurs, special type of cement with an

admixture or additive should be used, (after testing & proportioning)

Aggregates for shotcreting should be hard, dense and uniformly graded. The

percentage of grading shall be as specified/tested as per relevant IS.




The maximum aggregate size fractions of the ready mix should be determined

suitability tests as the size would depend upon thickness of shotcrete and spray

arrangement. In general nominal size of aggregate shall not exceed 10 mm.

The purity as well as uniformity of the aggregate fractions should be guaranteed as p

appropriate standards.

The application procedure shall be developed in the field to give minimum shrinka

cracks, no hollow area, and good adherence to the rock, smooth finish and low rebound.

Before shotcreting operation adequate ground wires/nails shall be installed to establ

boundaries/thickness of shotcrete.

Additives free from chloride have to be used to avoid steel corrosion or adverse eff

on strength development of shotcrete.

Before start of the work, proof should be furnished as to how the additive influenc

the strength development up to the point where the final strength is reached and in whproportion.

Water to be used in shotcrete should be fresh, clean and free from injurious amounts

sewage, oil, acids, alkali, salts and organic or other undesirable matter.

The method of application of shotcreting should be developed from both material a

technical point of view, satisfying all requirements.

The mixing equipment for dry process should be capable of thoroughly dry-mix

sand and cement within the time available to uniformly and continuously supply the mater

to the gun.

For wet process the mixing plant shall be capable of thoroughly mixing the specif

materials in sufficient quantity and accurate proportions to maintain continuous placing.

For routine quality control, test panels shall be sprayed alongside the area

placement and cores shall be cut from the panels for testing.

Tests for determining flexural strength and bond strength shall also be done as p

relevant IS.

In-situ cores shall also be extracted and tested for actual strength of in place shotcre

STRENGTH CRITERION

The specimen, in general, shall be cylinders with a height equal to twice the diame

of the cylinder. The core capping and compressive strength test shall be carried out in t




presence of Engineer-in-Charge. Test results from cores with height/diameter ration different

from 2.0 shall be converted to equivalent cylinder strength using the value given as below:

Height/diameter ratio of core Cube factor Cylinder factor

2.00 1.15 1.00

1.75 1.12 0.97

1.50 1.10 0.95

1.25 1.07 0.93

1.10 1.03 0.89

1.00 1.00 0.87

0.75 0.88 0.76

The 28-day-strength of plain shotcrete shall be minimum 25N/mm2.

The SFRS shall meet the following strength requirements:

Compressive strength on

Cylindrical cores 3 days < 10MPa

7 days < 18 MPa28 days < 30 MPa

(Equivalent cube strength of 28 days < 35 MPs)

Flexural Strength 28 days < 3.8 MPa

Toughness 28 days < 2.4 MPa

Bond Strength

Against intact rock 28 days < 0.5 MPa

Between two layers of SFRS 28 days < 1.0 MPa

10.1.9 GENERAL SPECIFICATIONS OF ROCK BOLTS/ANCHORS

Rock bolts of specified diameter shall be made from deformed bars conforming to IS:1786.

Diameter of hole shall be as specified for different types of bolts however, where full-column grouting is specified with the help of inject and return tubes the hole dia (except

for anchorage) length shall have to be suitably increased to accommodate these tubes.

Drill holes must be cleaned just prior to installation of the bolt to remove sludge rockdust, particles and debris present in the hole cleaning can be accomplished byintroducing compressed air @ 50psi at the back of the hole or be washing with water (ifthe rock is washable and then made dry by compressed air.

Prior to actual rock bolt installation, a series of test installations shall be carried out onall rock types which are representative of rocks likely to be encountered to prove

suitability/efficacy of rock bolt systems. These tests shall conform to the requirementslaid down in CBIP manual on rock Mechanics (May 1988) and IS: 11309.

All rock bolts shall be cleaned of dirt, detrimental rust, grease or any other deleterious

material to ensure proper bond with grout.

All rock bolts/ anchors shall have a minimum threaded length of 200mm for fixtures atthe excavated surface (end). All threaded parts of the bolt system shall be treated with abase lubricant, such as molybdenum.




When the rock bolts are to be used in conjunction with welded wire-mesh/chain lmesh, the wire mesh washer and extra nut shall be used to secure these with rock boWelded wire mesh/chain link mesh shall not be placed between rock and bearing platethe rock bolt.

Bearing plates for specified thickness and size shall be of mild steel conforming to 2062 (Grade-A.

Rock surface beneath the bearing plate shall be chipped smooth and covered with tcushion of smooth cement (quick set): sand mortar (1:1). When the bearing surfacebolt perpendicular to the hole axis, bevel washers shall be placed between plate and nto ensure a uniform bearing surface for the nut, normal to axis of rock bolt.

Nuts/washers used shall conform to IS: 1363. Hardened flat washers shall be usbetween the bevel washers and the nut in all cases.

Metallic/PVC tubes shall be used for grout injection and air vent pipes wherever specifi

Perfotubes shall be of standard quality non corrosive mild steel of thickness not less th1 mm and shall have adequate perforations for mortar to extrude and fill the hcompletely.

Cement shall be ordinary Portland cement conforming to IS:269, IS:81

Cement/admixtures shall be used well within their respective specified effective span(s) with reference to manufacturing date and in the order in which these adelivered at site and shall be free from lumps formed on account for warehouse storage

Pump for grouting shall permit control of pressure, allow a flexible rate of injection abe designed to minimize clogging of valves and ports.

Resin cartridges shall conform to relevant Indian standards or where not covered these standards, to the equivalent international standards. The data sheet for use of recartridges shall be obtained from the manufacturer for better results. Checks must abe established to ensure that resin is used within the limit of its active storage (specified effective life span).

Bolts fixed within 10m of a blasting operation shall be retightened (retensioned) to t

specific value as mentioned in note xxii before full column grouting. Expansion shell of requisite dimension shall conform to IS: 2062 (Grade- A) “ Block

malleable iron casting”. The size/dimension of expansion shell shall be finalized af

conducting the “Pull -out-Test ” at the place of installation (in different rock mcategories).

For resin grouted rock bolt one end of the bar shall be chamfered and other shallthreaded (preferable rolled over the specified lengths).

Perfo bolts shall be used in saturated rock mass, where specified and as directed by

Engineer-In-Charge.

Perfo sleeve shall be filled with (1:1) sand cement mixture.

0.5 % to 1.0 % by weight of cement admixture for quick setting and workability shall added for the perfo cement mortar.

Perfo bolts hall not be tensioned.

For grouting a readily pumpable cement grout with water cement ration of 0.50 t0 0shall be used.

Since setting time of resin is sensitive to temperature, the resin capsules must be storedensure temperature compatibility with the resin formulation and viscosity, prior actual installation at work.




Slow setting resin shall normally have a setting time of approximately 20-30 minutes.

Quick setting resin shall normally have a setting time of approximately 30secs.

Quick setting resin capsules shall be inserted into the hole over the specified length withthe help of a special loading stick only.

In the upward holes, the use of packer shall be made to prevent the flow of resin catalystmixture beyond the specified anchorage length.

Threads of bolts and nuts hall be prepared as per requirements of IS: 1368. To avoid clogging of tubes the grout must be passed through IS: 2.36 mm screen prior to

injection.

Grouting shall be continued till there is full return of the grout through the air vent/groutreturn tube.

It shall be ensured that entire surface of the embedded portion of anchor bars/rock boltshall be in intimate contact with the mortar/grout.

Special care shall be taken against movement of the bars until the grout has taken finalset.

Pull-out test on rock bolts hall be carried out in accordance with IS: 11309 and randomly(percentage shall be decided by Engineer-in-charge) tested up-to the design load of

11.00 tones & 17.00 tonnes for 25mm & 32 mm dia rock bolts respectively. If any one ofthe rock bolt fails, all adjacent rock bolts shall be tested or as directed by the Engineer-in-charge. If it is found that any bolt fails or does not take the required tension withoutanchorage slip, a new bolt shall be installed in the close vicinity of the unsatisfactory boltand the unsatisfactory bolt shall also be full column grouted.

Rock bolts where specified shall be tensioned up-to 7.0 & 11.00 metric tones for 25 & 32 Øbars, respectively with Hydraulic pensioner torque wrench shall not be used.

Suitable admixtures such as aluminum powder shall be used to produce a slow settingmortar. The quality of such admixture shall be determined by the laboratory testing.

In grouted anchor bars of length more than 4.0 meters the bar shall be pushed into thehole about half way and then given a slight bend (around 10) before pushing it fully intothe hole, to ensure that the anchor is firmly lodged in the hole while the grout sets.

Insertion of the bolt into the hole and mixing of resin and the hardener must becompleted within the setting time of resin at the end.

10.1.10 Support Elements

Welded wire mesh serves as the standard reinforcement for shotcrete linings and

facilitates the application of shotcrete as well as improves the post-failure behaviour of

shotcrete.

Preferably mesh 100X100 mm, 5mm diameter of structural steel having minimum

yield strength of 420 N/mm2 should be used.

Reinforcing steel bars shall be attached securely to the previously placed shotcretelayer or wire mesh with overlaps as per execution drawings.

Steel ribs are used to support the underground excavation as an immediate protection

and subsequently act as reinforcement and load distributing members for concrete lining.

For steel ribs, structural steel should have minimum yield strength of 240N/mm2 and

comply with relevant IS.




Lattice girders should be manufactured from corrugated reinforcing bars.

For welding, manual metal-arc process shall be employed with covered electrodes

per relevant IS.

Forepoling is the installation of advance-support ahead of the tunnelling face

prevent and protect the ground deformations in the loose strata and it depends, to a h

extent, on the quality of workmanship.

The use of steel ribs is a precondition for the installation of the advance-support a

the combination of steel ribs with shotcrete forms the support of the advance-support at

place of the nearest rib to the face.

The method and type of forepoling viz. steel pipes, spiles etc. shall be as specified /

per execution drawings.

Steel lagging is employed mainly in weak ground with low cohesion to prevent t

collapse of material during and immediately after excavation.

The thickness and length of steel lagging sheets shall be as specified. Voids and ga

behind the lagging sheets should be either filled with shotcrete or by suitable cont

grouting.10.2CEMENT CONCRETE WORK

IS CODES: - 383, 269, 2116, 2386, 2430, 456, 516, 1199, 4634, 9103.

It is necessary to exercise supervision and control of quality & workmanship for

concreting work viz site-mixed concrete, pre-cast, plain & reinforced concrete compone

and readily-mixed concrete.

A number of operations must be carried out on the ingredients of concrete to conv

them into a cohesive mix and these operations will determine the strength, durability a

appearance of the finished concrete.

10.2.1Proportioning, Batching & Mixing

Concrete has to be manufactured in batching mixing plants whose number, capacit

and locations should be determined as per requirements of the project components.

As a rule, aggregate should be batched by weight to produce concrete of unifo

quality. The batching of aggregate or of individual particle size fractions by volume shall

permissible only if automatic proportioning devices are used.

If volume batching is applied, the weight of the batched particle size fractions sho

be checked frequently even if automatic devices are used.

Mixing instructions are to be legibly displayed at the mixing plant which shou

comprise the following: -

Strength class of concrete.

Type, strength and quantity of aggregate, with indication of quantities of size fractionsbe batched separately or the indication of ‘ready -mixed aggregate’.

Consistency of fresh concrete.

Type and quantity of admixtures and additives, if any.

Water/Cement ratio.

Water content (mixing water & surface moisture of the aggregate).




A simple and convenient system (scales) of varying accurately the material supply to

the concrete mixers has to be installed, with a suitable metering system to ensure that the

amount fed into the machine can be controlled, ascertained and recoded.

Sufficient test weights should be kept available for checking the accuracy of all scales.

Trial operation of the batching and mixing plant has to be made to check its

operational efficiency as specified in the technical specifications.

Batched material should be measured within specified tolerances as per ACI Concrete

Manual, 304R (Guide for measuring, mixing, transporting and placing concrete) unless

specified otherwise in the technical specifications and should be discharged into mixer

without loss.

Record of each batch should be available for check indicating the number of batch, size,

mix code, time & date, weight of each aggregate, weight/volume of water, moisture content,

volume of admixture & its type etc.

The mixer should not be discharged in excess of the capacity recommended by the

manufacturer. Excessive over- mixing requiring additions of water is not permissible.

Over mixing is objectionable because the grinding action increases fines, therebyrequiring more water to maintain consistency of concrete and also driving out entrained air.

The minimum mixing time recommended should be as per USBR concrete manual,

unless otherwise specified. However the mixing time should not exceed three times the

number of minutes given below: -

Recommended Minimum Mixing Time

Capacity of mixer (m3 ) Time of mixing (minutes)

Up to 1.5 1.5

Beyond 1.5 & up to 2.0 2.0

Beyond 2.0 & up to 3.0 2.5

Beyond 3.0 & up to 4.5 2.75

In addition to the accurate weighing, another important objective of successful

batching is the proper sequencing and blending of ingredients during charging of the mixer.

The number of revolutions of the drum/pan has a direct bearing on the uniformity ofmixing. Mixers should be operated approximately at the speed at which they were designed.

The ability of a mixer to mix concrete properly is determined by mixing efficiency tests.

The uniformity of fresh concrete is evaluated in accordance with the method specified in IS:

4634-1968.

10.2.2Concrete Mix Design

The composition of the concrete mix design (controlled concrete) shall comply with

the requirements laid down in the approved standards.

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.




The concrete mix shall generally comply with the following requirements for vario

basic mixes of grade M10 and higher: -

Class Strength (N/mm2

after 28 days)

Minimum cement content to ensure

durability (kg/m3)

W/C Ratio

M:10

M:15

M:20M:25

M:30

M:40

M:50

M:60

M:70

10

15

2025

30

40

50

60

70

220

240

260(Plain) / 300(RCC)280(Plain) / 300(RCC)

320(RCC)

360(RCC)

0.60

0.60

0.45 / 0.550.40 / 0.50

0.45

0.40

Adjustment to minimum cement content for aggregate other than 20mm nominal size shall

as under: -

Sr. No. Nominal maximum aggregate

size (mm)

Adjustment to minimum cement content in

table above (kg/m3)1. 10 + 40

2. 20 0

3. 40 - 30

Adjustment to minimum cement content derived by trial mixes to reach a cert

concrete strength has to be checked against the minimum cement content for the requirem

of durability and the greater of the two has to be adopted.

Trial tests for determining the mix design are to be performed before starting concreting work and also as a continuous quality control during execution of all the concretiworks till the values of water-cement ratio, bleeding in concrete, tensile strength etc. are

accordance with the relevant standards.Production of concrete of excessive slump or adding water in excess of design W

ratio to compensate for slump loss resulting from delays in delivery or placing is prohibited

Acceptance of concrete mixes – Concrete mixes shall be rejected if they fail to meet o

or more requirements related to any of the following: -

Improper class of concrete.

Non-workability.

Over mixing.

Air content, slump or temperature not within specified limits.

Maximum water- cement ratio is exceeded.

Foreign material in concrete. Total time limits are exceeded as specified in standards.

Concrete to be placed by pumping particularly in relatively inaccessible locations a

in thin sections (where reinforcement is heavy or congested or where high pouring rates a

required to avoid cold joints), the design of mixes need special care including control

proper grading of aggregates and workability through use of super- plasticizers, whe

necessary.




10.2.3Water cement ratio (W/C)

Water cement ratio is one of the key elements for a durable and sound concrete of

adequate strength.

W/C is the ratio of the water content “W” to the weight “C” of the cement in concrete.The concrete should not be made with a W/C ratio higher than that established in the

preliminary tests.The W/C ratio should be checked (for each type of concrete) at the time of first placing

and thereafter atleast once daily.

The average of three consecutive W/C ratio determinations should not exceed the W/C

ratio established for a particular type of concrete in the preliminary tests, and individual

values shall not exceed it by more than 10%.

Water cement ratio should be maintained at correct value. The water contents in both

fine and coarse aggregate have to be determined regularly. The amount of added water should

be adjusted to compensate for any observed variation in moisture content.

For reinforced concrete, with respect to corrosion protection of steel, the W/C ratio

should not exceed 0.75 if compressive strength of cement is 35 N/mm2 atleast.

10.2.4Durability of concrete

It is essential that the concrete be durable viz. it should perform satisfactorily in the

working environment in its anticipated exposure conditions during service.

The materials and mix proportions are to be such as to maintain the integrity of

concrete, and to protect embedded metal / reinforcement from corrosion.

The different environmental exposure conditions (as per Table 3 of IS 456: 2000) are

given below: -

Sr. No. Environment Exposure condition1. Mild

Concrete surfaces protected against weather or aggressive conditions,except those situated in coastal area.

2. Moderate

Concrete surfaces sheltered from severe rain or freezing whilst wet.

Concrete exposed to condensation and rain.

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.

3. Severe Concrete surfaces exposed to severe rain, alternate wetting and drying,or occasional freezing whilst wet or severe condensation.

Concrete completely immersed in sea water.

Concrete exposed to coastal environment.

4. Very Severe

Concrete surfaces exposed to sea water spray, corrosive fumes orsevere freezing conditions whilst wet.

Concrete in contact with or buried under aggressive subsoil / groundwater; concrete exposed to alternate wetting & drying.

5. Extreme Surface of members in tidal zone.

Members in direct contact with liquid / solid aggressive chemicals.




10.2.5Workability of concrete

The concrete mix proportions chosen should be such that the concrete is of adequ

workability (consistency) for the placing conditions of the concrete and can be prope

compacted.

Loss of workability is a critical factor which should be considered while assessin

suitable time limit between mixing and the final hauling/placing of concrete.

The reduction in workability of concrete is due to loss of water by evaporati

hydration of cement and absorption of water by aggregates; hence the concrete should

placed as soon after it has been mixed as practicable.

Tests for compaction factor, Slump etc. for good workability of concrete should

carried out as per mix design / as per IS: 456-2000 and other relevant standards.

The slump of concrete, after pouring but before it has set, should not exceed the valu

specified below: -

Concrete Uses Slump (cm)

Massive structures 5Slabs and tunnel inverts 5

Walls, piers, columns, parapets, curbs, beams 10

Sidewalls and tunnel linings 10

Other structures 7.5

10.2.6Transporting of concrete

Concrete should be transported from the mixer to the site of placement as quickly

possible by methods, which shall prevent segregation or loss of ingredients and maintain t

requisite workability.

The conveying equipment must have the capacity to move concrete so that cold joiare eliminated.

The method of transportation used should efficiently deliver the concrete to the po

of placement without significantly altering its desired properties with regard to water-cem

ratio, slump, air content and homogeneity.

Each method of transportation has advantage under particular conditions of u

pertaining to mix materials and design, type & accessibility of placement, required delive

capacity, location of batching plant etc. These various conditions should be carefully review

in selecting the type of transportation best suited for economically obtaining quality

concrete in place.

During transit, the fresh concrete should be protected from harmful climatic effects

hot weather the temperature of fresh concrete shall not exceed 300C.

Transportation of concrete in ordinary open tippers or trucks shall not be allowed a

causes segregation. Transit concrete mixers shall be used for transportation. Self loadi

batching, mixing & transporting mixers can also be used both for mixing and transporti

concrete.




10.2.7Placing & Compacting of concrete

The concrete should be placed and compacted as thoroughly as possible with vibrators

before initial setting of concrete commences and shall not be subsequently disturbed.

Compaction of concrete aims at removing all trapped air, thereby achieving maximum

contact between the materials within the concrete. This results in maximum strength and

density, and an effective bond between the concrete and any reinforcement present.

The importance of adequate compaction can be demonstrated by the fact that for every

1% of air voids left trapped in concrete, there is a 5% reduction in the compressive strength

of the mix.

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 should be strictly avoided. Spare

vibrators shall be kept as stand by. Temperature of concrete, as placed, should be restricted to300C to avoid impairment of quality, durability and other properties.

All cold weather precautions and protective measures, as specified, should be taken to

ensure that loss of strength of concrete does not occur owing to cold weather.

Rock surface upon which concrete is to be placed should be prepared by roughening

where necessary, followed by thorough cleaning and any further preparation as may be

specified.

10.2.8Curing of concrete

Curing shall commence as soon as possible after concrete is placed and initial set has

occurred but before it has hardened.

Curing should be continued for at least 7 days in general.

Exposed surfaces of concrete should be kept continuously in a damp/wet condition by

pounding or by suitable covering.

For curing compounds and control, refer Chapter XII.

10.2.9Sampling & testing for compressive strength of designed mix concrete

Sampling

A random sampling procedure is to be adopted to ensure that each concrete batch shall

have a reasonable chance of being tested, i.e. the sampling should be spread over the entire

period of concreting and cover all mixing units (concrete production units).

A sample of concrete shall be taken at random on eight separate occasions during each

of the first 5 days of using a mix (total 40 specimens for test cubes).

40 Individual Cube results, each representing separate batches of similar concrete

produced by the same plant and under the same supervision, will give the standard deviation.




Thereafter, one sample will be taken at random from every group of 25 batches ma

by each batching plant, for each grade of concrete, and atleast one sample will be taken

each day on which any concrete of a particular grade is made.

Additional samples will be taken for test Cylinders. These samples will be from eve

100 batches or atleast once a week during concreting operations. Two cylinders will be cast

determine the indirect tensile strength of the concrete at 7 days and 28 days, as specifiedthe respective standard. Sampling should coincide with samples taken for test cubes.

The frequency of sampling may be varied at the discretion of the constructi

engineer.

Testing for compressive strength:

From each sample, two specimens (cubes or cylinders) shall be made for compress

strength testing at 28 days. Another specimen may be taken for testing at 7 days for cont

purposes.

The mean of the specimen strengths of the two specimens made from the same samshall be the 28-day specimen result.

For mass concrete one specimen shall be provided for testing at 90 days.

10.2.10 Acceptance criteria of compressive strength

The concrete shall be deemed to comply with the strength requirements wh

conditions are met as per IS: 456-2000

If the range of individual cube strength made from the same sample exceeds 15%

the mean specimen strength then the method of making, curing and testing of cubes shall

examined thoroughly.

In the event of a result having a range exceeding 20%, then the result shall unacceptable & invalid.

Similarly the results shall be unacceptable if 3 or more results in 40 are belo

characteristic compressive strength (fck) or one result in 40 is less than 85% of fck. [fck is

Characteristic compressive strength of 150mm cube at 28 days in N/mm2. For M15 & M

grades, fck is 15N/mm2 and 20N/mm2 respectively.]

When the results are unacceptable, the following action shall be warranted

the construction as well as quality control unit units: -

Checking of the mix and improvement to the standard of quality control.

Cutting of test cylinders from the concrete for examination and testing of specime prepared there from.

Carrying out load tests on areas/structural members containing the suspect concrete.

Cutting out and replacement of defective concrete volumes.

Carrying out non-destructive tests/drilled cores to assess the in-situ quality of the suspconcrete.




10.2.11 Additional Tests

Concrete shall be tested, if specified, for the following characteristics and remain

within acceptable limits as specified & as per approved standards: -

Drying Shrinkage.

Water Absorption.

Moisture Movement.

Stripping times of Formwork. Duration of Curing.

10.2.12Quality Control of Fresh ConcreteTo ensure uniform concrete quality, the fresh concrete shall be continuously checked

on site during concreting operations for the following properties: -

Consistency (spread or slump).

Workability.

Air content.

Volume/weight (wet and dry density).

Water and cement content (water-cement ratio).

Aggregate content.

Bleeding in accordance with relevant standards.

Such tests shall be performed over a period covering the whole concreting operations

of each section.

The fresh concrete properties shall be checked at frequent intervals at the beginning of

a concreting section and when concrete is poured during night shifts.

The quantities required for quality control of the fresh concrete shall be taken from the

concrete mixing plant, not from the point of final placement.

10.2.13Construction joints

Adequately strong and dense bonding of the concrete layers in construction joints

should be ensured.

To develop proper bond between the lifts, the concrete surface shall be freed of all dirt,

laitance, coating stains, defective concrete and all foreign material. The surface shall be

roughened and damped prior to covering with fresh concrete. This can be achieved by doing

green-cutting at the proper time for construction joints.

Concreting should be carried out continuously up to the construction joints so that

each section of concrete is completed without any lapse while the work is in hand.

In water retaining structures, all construction joints require the use of an approved

type of water stop to seal the joint at the liquid face. Water stops are also generally installed

for construction joints in tunnel concrete linings.

Wet sand blasting or high- pressure water blast shall be used for preparing the jointsurfaces to receive the next lift. The process to be adopted shall be as specified in the

specifications.

In case any doubt exists over the soundness of the joint, then all steps considered

necessary to investigate and remedy the defects are required to be taken immediately.

Care should be taken to prevent undercutting and loosening of aggregate in the

concrete.




CHAPTER XI

IMPORTANT DO’S AND DON’TS/CHECK LIST FOR

UNDERGROUND WORKS

Sr. No. DO’S DON’T’S

1. Before commencement of excavation, verify alllines, grades, dimensions, setting out of the work

of tunnels, shafts & caverns with the execution

drawings.

2. Ensure adequate understanding of NATM (New

ustrian Tunnelling Method) for its application for

supporting system.

3. Check that all lighting arrangements including

traffic lights are provided as specified during

underground excavation.

4. Ensure that ventilation system is of sufficient

capacity to maintain adequate supply of

uncontaminated air in the underground execution

throughout the construction period.

Don’t allow operation

installations and equipme

during tunnelling unless necess

facilities to remove all noxio

gases as per specifications ha

been provided. Underground u

of internal combustion engin

burning gasoline or liquef

petroleum gases should not

allowed.

5. Ensure availability of an emergency system to

allow evacuation of personnel and equipment in

case the ventilators fail.

6. Ensure installation of approved lightning

indication system in the vicinity of tunnel portals.

7. For safety and security of the works, ensure that

the tunnel excavation is continuous by day and

night.

Don’t allow intermissions tunnel excavation until all

support elements at the particu

locations have been completed.

8. Ensure that the excavated muck from tunnels is

placed at the identified areas in the manner as

specified.

Don’t allow the contractor to uthe excavated muck fr

tunnelling on other works unl

otherwise approved.9. Make sure that the drilling and blasting techniques

being used by the contractor for different rock

conditions are based on the field trials / blasting

design.

Don’t allow charging and blastactivities during thunderstorms

similar environments.

Don’t allow use of any explosivwithout the express permission

authorities concerned.




10. Ensure that any damage caused by improper

blasting is repaired immediately and any unstable

or loose material appearing during excavation is

removed.

Don’t permit blasting by personsother than licensed experts.

No disintegration and loosening of

rock mass around the excavated

tunnel should be allowed.

11. Make sure that all blasting events are recorded

along with details.

Don’t forget to perform the ‘Alarm

system’ and ‘All clear’ signal before,during & after blasting operations.

12. Ensure transport of explosives in the approved

explosive van as per regulations in force.

Don’t allow preparation of chargesinside the tunnel.

13. Inspect the surfaces of excavated sections to

determine the quality and conditions of supports

as the excavation advances.

Don’t allow excavations andinstallation of support elements

without prior approval of working

cycles of respective ground

conditions.

14. Ensure drilling of feeler or pilot holes ahead of

excavation, wherever necessary, to determine in

advance the nature of materials to be excavated orthe existence of natural cavities or faults or water

or gases.

Don’t allow over- excavation

beyond the specified limits &

payment lines.

15. Strictly check that all the protective and safety

measures including firefighting equipment as

required have been provided.

Don’t allow excavation to proceed ifany lack of compliance is observed

ith regard to the requisite

protective and safety measures.

16. Maintain access to the site for emergency vehicles

at all times.

17. Ensure adequate maintenance and calibration of

all geotechnical instruments installed.

Don’t let the persons other thangeotechnical experts handle these

instruments.18. Take all necessary precautions so that the

instruments are not damaged.

19. Before shotcreting/concreting begins, ensure

availability of a work progress chart giving details

of work operations, calibration of batching and

mixing plant & procedures to produce best quality

product.

Unsatisfactory equipment viz

shotcreting machines, concrete

pumps, nozzles, dosage pumps and

mixing plant etc. having

insufficient capacity and

inadequate operational quality

should not be allowed to be used.

20. Ensure compatibility of accelerating admixtures

only after lab tests.

Don’t allow use of accelerating

agents having chloride content as

these can aggravate steel corrosion

or adversely affect the strength

development of shotcrete.

21. Make sure that the minimum cement content &

compressive strength of shotcrete complies with

minimum M: 25 concrete.

No loose or clogged material or

any adherent rebound from

previous shotcreting should be




allowed to remain on the surf

when fresh shotcrete is sprayed

22. Ensure that all steel parts such as wire, reinforcing

steel, mesh, ribs etc. are covered neatly with at

least 3 cm of shotcrete.

The mixing time of cement a

aggregates for shotcrete shall n

be less than 60 seconds a

shotcreting should not be allow

unless placing can be completwithin a period of 90 minutes fr

the time of mixing.

23. Prevent dust & slush formation as much as

possible during spraying of shotcrete.

24. Make sure that aggregates for shotcreting are

stored in sufficient quantities and in proper

manner so that purity and aggregate composition

remain unchanged.

25. The water-cement ratio of fresh shotcrete in place

should be kept between 0.35 and 0.50.

Don’t, at all, ignore taking necesscourse of action as specified, in c

the cores of shotcrete fail and domeet the strength requirements.

To ensure that: -

Minimum of shrinkage cracks and as smooth finished surface as possible.

All tunnelling steel supports to be used are as per specifications & pre-tested for quality.

Supports can be in the form of wire mesh (welded wire fabrics), reinforcing steel bars, rties, rock bolts, anchors, steel ribs, lattice girders, advance supports (fore poling pipes, spietc.),steel lagging sheets etc.

No concreting work should be started unless all the I.S. and international standards ha

been agreed upon.

Before concreting work is commenced, Verify that all design dimensions and levels are as pexecution drawings.

Concrete work and reinforcing steel work is carried out strictly in accordance with tquality control of the materials employed and in conformity with the execution drawings.

Adequate means are available to protect the fresh concrete from running water, rain, frovibrations, hot & cold weather conditions or other detrimental impacts.

All equipment, plant, tools, facilities are available & operational to warrant uninterrupconcreting work for the part or section in commencement of important welding operatioat the site.

Constant records of all important data regarding the quality and stability of the structuare kept at site e.g. periods of individual concrete operations, air temperatures & weathconditions, test specimens, test results of concrete strengths, water-cement ratio, cemeaggregates, mix proportions, welds in reinforcing bars etc.

Aggregates for concrete are obtained from the specified quarries only & quarry site shall

inspected periodically.

In no case should concreting of any lift be started unless sufficient aggregate is on handcomplete the lift.




CHAPTER XII

CONTROL ON CONCRETE MATERIALS

The strength ultimately achieved by concrete is governed by many factors, the

foremost among them being the characteristics of its ingredients.

Lack of uniformity in the ingredients is a major cause of variation in concrete quality. Itis therefore essential to minimize variations in the ingredients to manufacture concrete of

fairly uniform quality.

The concrete ingredients comprise

Cement. Aggregates. Water.

Chemical Admixture. Curing Compounds.

Control on quality of these materials is explained hereunder: -

12.1 Cement

12.1.1 Source of cement

Cements from different sources display variations in their strength characteristics.

Cement from the same source may also show significant differences in properties over a

period between batches and production.

When process and quality controls in the cement plants is adequate, in-plant variation

between batches up to 8% (coefficient of variation in strength) can be expected.

A relatively higher coefficient of variation is often observed in the cements

manufactured in our country, it is therefore recommended that the project authorities

including QA/QC officials should visit the cement plants once in six months to: -

Follow-up the quality of cement being produced and supplied for project construction.

Study various operations of cement manufacturing and monitor the testing facilities at

the plant laboratory particularly the following, and suggest improvements to minimize

the variations;

Level of alkali content. Quality and quantities of puzzolanas. Free lime in clinker.

Use & quality of dry fly ash. Testing for heat hydration etc.

12.1.2 Storage and Handling of Cement

The following guidelines for storage and handling of cement should be followed: -

Cement should be stored in water tight buildings, bins or silos which will exclude

moisture and contaminants.

Cement bags should not be stored on damp floors and should rest on pellets.

Cement bags should be stacked close together to reduce air circulation, and should not

be stacked against walls.

Cement bags to be stored for long periods should be covered with water-proof

covering.




On smaller or the jobs where no shed is available, bags should be placed on rais

wooden platforms and covered with water proofing material.

Cement stored for longer periods may develop ‘warehouse pack’ (sort of hardnewhich can be corrected by rolling the bags on the floor.

At the time of use, cement should be free-flowing and free of lumps.

If the lumps do not break easily, the cement should be tested afresh before use.

When removing bags for use, the oldest cement should be taken out first. Cement more than three months old should be tested afresh before use.

When bulk cement is to be hauled in open trucks, it should be thoroughly protec

from moisture and wind.

12.2Aggregates

12.2.1Aggregate Characteristics

The aggregate characteristics significant to concrete technology are deriv

from microstructure of materials, prior exposure and processing factors.

Based on above factors, the aggregates can be divided into following groups: -

Characteristics dependent on porosity: Density, Moisture absorption, Strength, HardneElastic modulus and Soundness.

Characteristics dependent on prior exposure and processing factors: Particle size, Shaand Surface texture.

Characteristics dependent on chemical and mineralogical composition: StrengHardness, Elastic modulus and Deleterious substances.

12.2.2Quality of Aggregates

The quality of aggregates for the production of concrete largely depends up

appropriate specifications, effective selection and handling.

Aggregates as delivered to the weigh batchers or batching and mixing plant should

of good quality and uniform in grading.

The most important physical characteristics of an aggregate and their significan

limits for its control are briefly described below: -

Strength: At least as strong as the specified strength of cement matrix.

Cleanliness: Free from dust, mica, clay and organic impurities which adversely aff

strength and durability.

Porosity: A porous aggregate will tend to produce a porous concrete. Some poros

however, results in a higher bond between aggregate and the cement paste.

Particle shape: Flakiness (crisp fragments) reduces the workability and hence calls

greater cement content in the mix. Percentage of unfavourable shapes (flat & elongat

particles) should not exceed 30% by weight. Special care should be taken in the design

concrete mix if this limit exceeds.

Roughness: It leads to some loss in workability; however a rough surface provide

better bond with the cement matrix.




Grading: IS: 383-1970 (Tables 2 & 4) is the guideline for passes in % by weight through

sieves. If several fractions are mixed, the passages should not deviate from grading curve

by more than 5% of the total weight.

Reactivity: It is inert in relation to the cement chemistry and environment. Avoid using

aggregate containing soluble silica such as opal, chert or containing excessive quartz

which reacts strongly with the highly alkaline cement & can set up disruptive pressure

within concrete.Other deleterious substances:

Less than 2% mica mixed with other deleterious substances. Less than 2% of coal or other expanding components. No compound which will inhibit setting and hardening of concrete and reduce its

strength by more than 10%. No deleterious amount of salt which will reduce the protection of reinforcement against

corrosion.

No soluble salts which may result in efflorescence (white crystalline or powdery depositon concrete) or may corrode the reinforcement and affect the setting time.

Avoid Sulphide minerals since they lead to ‘rust staining’ on finished concrete.

Avoid aggregates having a high dry shrinkage as they can result in rapid deterioration ofconcrete viz cracks and excessive deflection.

Also refer to 12.2.4 regarding harmful materials in aggregates.

12.2.3 Control on gradation of Coarse and Fine aggregates

The overall grading of an aggregate has a significant effect on the economy of

producing concrete mix with the specified strength.

Coarse and fine aggregates having considerable range of grading can be used equally

well to produce concrete of the same workability and strength provided these are used in

relative proportions of desired overall grading.

Control on undersize materials: Coarse aggregate

For effective control of gradation, it is essential that handling operations do notsignificantly increase the undersize in concrete.

The gradation of aggregate as it enters the concrete mixer should be uniform and withinspecified limits.

Screen analysis (particle size distribution) of the coarse aggregate should be made frequently to assure that grading requirements are met.

Rescreening the coarse aggregate at the batching plant will effectively eliminate or

reduce the objectionable undersize materials when handling methods are not

satisfactory. Fine aggregate

Variations in grading of fine aggregates shall be controlled by keeping finer fractionsuniform and exercising care to avoid excessive removal of fines during processing.

The amount and nature of materials finer than 75 μm should be given special attention.

Excessive quantities of such material increase the mixing water requirement, rate ofslump loss, drying shrinkage and thus decrease the strength.




Different size fractions should be blended/mixed as they flow into a stream frregulating gates or feeders in the plant. The most positive method of control for a wrange of plant and job condition is separate storage, handling and batching of the fand coarse fractions.

12.2.4 Harmful materials in aggregates

The effects of harmful materials present in aggregates should be well understood

that these can be adequately controlled. The effects are given below;

Sr. No. Harmful Materials/Substances Effect on concrete

1. Organic impurities. Affect setting & hardening causing

deterioration.

2. Material finer than 90μm. Affects bond, increases water requirement.

3. Coal, lignite and other light weight

material.

Affect durability, causes stains/pop outs.

4. Soft particles. Affect durability.

5. Clay lumps & friable particles. Affect workability & durability & pop outs.

6. Alkali reactive aggregates. Abnormal expansion, map-pattern cracking

12.2.5Sampling of aggregate

Samples of finished aggregate for test should be representative of the sum of mater

as it will be when batched and mixed.

Samples may be taken from conveyor, bins, cars, stockpiles etc. and in accordance w

the methods of selecting test samples of aggregates as given in IS: 2430-1986.

12.2.6 Storage & handling of aggregates

Aggregate should be handled and stored in a manner that it minimizes segregation a

prevents contamination by deleterious substances.

Stockpiles should be built by layers of uniform thickness and the floor of the stockpshall be shaped to a uniform smooth surface.

Partition between adjoining compartments should be high enough to prev

intermixing of materials. To ensure that this condition is met, any test for determini

conformance to requirement for cleanness and gravity should be performed on t

sample secured from aggregates at the point of batching.

Stockpiles should not be constructed at locations or methods that will interfere

damage any utilities such as power lines, telephone lines, pipe lines, and undergrou

utilities.

The side slopes of the stockpile shall not be steeper than 1.5 (H):1 (V).

12.3 Water

A popular criterion as to the suitability of water for manufacturing concrete is “If wais fit for drinking it is fit for making concrete”.

But this criterion does not appear to be the basis for evaluation since water containi

small amount of sugar or citrate is suitable for drinking but not for making concrete. On t




other hand, water containing certain biological impurities may not be potable but may be

acceptable for use in concrete.

An acceptable limit of impurities depends primarily upon the quality of concrete and

exposure to weathering.

The guidelines for acceptable quality of water for mixing and curing concrete are

specified in IS: 456 for plain and reinforced concrete and IS: 1373 for pre-stressed

concrete.

12.4 Chemical Admixtures

12.4.1 Need for use of admixtures

An admixture is a material other than water, aggregates, hydraulic cement and fiber

reinforcement used as an ingredient of concrete or mortar, and added to the batch

immediately before or during or after mixing.

Admixtures are generally used to modify the properties of fresh and hardened

concrete, mortar and grout.

The most common reasons of using an admixture are to alter the workability, control

setting, pumping qualities or strength development of concrete or to facilitate reuse of

forms or improve appearance.

When specifying/using admixtures, careful attention should be given to the

manufacturer’s instructions as well as the possible adverse effects of combining more

than one admixture.

12.4.2 Classification of admixtures & their function in concrete

Sr. No. Type of admixture Function in concrete

1. Type I - Accelerating Accelerates setting time and earlydevelopment of strength.

2. Type II - Retarding Retards setting of concrete.

3. Type III - Water reducing Reduces the quantity of net mixing water

required to produce concrete of a given

consistency relative to the water content of an

equivalent concrete mixture at nominally

equal air content.

4. Type IV - Air entraining Causes air to be incorporated in the form of

small bubbles to improve workability and

frost resistance.

12.4.3 Physical requirements of admixtures

Concrete with admixture should be tested for water requirement, time of setting,

compressive strength, length of change after days of drying and bleeding, relative to

that of a reference concrete not containing chemical admixture.

Admixtures to be used for use in concrete should meet the specifications of IS: 9103.




12.4.4 Uniformity requirements of admixtures

Any batch of admixture shall have the same composition as that of the admixtu

tested for acceptance.

Sr.No. Characteristic Method Requirement Test(ASTM

Standard)

1. Water retention Loss of water not more than 0.55

kg/m2 of surface in 72 hrs.

C 156

2. Reflectance (white pigmented

compound)

Exhibit a day light reflectance of

not less than 60% of that of Mgo.

E 97

3. Drying time

Dry to touch

Tracky or track off concrete

when walked upon

Within 4 hrs.

Within 12 hrs.

E 97

4. Long term setting Rating between 4 to 10 D 1309/D 865. Non-volatile content

Class A (Natural or petroleum

based)

Class B (Resin materials)

D 1644

Admixture uniformity test requirements

Admixture tests shall be in accordance with British Standard

BA: Part 3:1985 and satisfy the requirements as given below: -

Sr. No. Characteristics Permissible deviation from the value stated b

the manufacturer

1. Dry material content

Liquid admixtures

Solid admixtures

3%

5%

2. Ash content Admixtures containing chloride content give v

variable results for content therefore test a

requirement may be waived for admixtures wh

contain more than 1% of chloride content.

3. Relative density

(Liquid admixture)

(-+) 0.02%

4. Super Plasticizer ASTM: C 494

12.4.5 Curing Compounds

Concrete must be properly cured to develop optimum properties and for adequ

supply of moisture to ensure sufficient hydration to a level that the desired strength a

durability can be achieved.




The methods and materials for curing are as under: -

Water Curing: For supply of additional moisture as well as prevention of moisture loss.

Sealed Curing: To prevent loss of moisture only.

Materials for curing

Water proofed paper, plastic sheeting and curing membrane are the most commonly

used materials for sealed curing.

Water proofed paper or plastic sheeting should be applied as soon as the surface has

hardened sufficiently to prevent surface damage and after the concrete has been

thoroughly wetted.

Specifications for sheet materials are given in ASTM: C171.

Membrane-forming curing compounds are formulated from resins, waxes or synthetic

rubbers dissolved in a volatile solvent or emulsified in water.

Curing compounds shall be applied, immediately after final finishing of concrete, by

hand-operated or power driven spray equipment to give smooth even surface. Theconcrete surface normally should be damp when coating is applied.

Upon removal of the solvent by evaporation, an almost impermeable membrane forms

on the surface and seals the concrete against the moisture loss. White pigment added

to the formulation will reduce absorption of heat and to see that complete curing has

been applied.

Curing compounds can prevent bond between hardened and fresh concrete or other

floor surfacing materials. When bond is necessary, either they should not be used or

the compound selected should be high strength bonding agent with high solid

contents.

Specification requirements for membrane curing compounds are given in ASTM: C309.




CHAPTER – XIII

MONITORING THROUGH CONTROL CHARTS

Monitoring of quality control and assessment of the trend of quality control be

exercised by the Project management is best done through control charts. Control charts ar

very convenient device to keep track of monitoring of a random variable for quality cont

purposes.

Preparation of quality control reports and control charts is considered to be a v

step towards the process of achieving good construction quality. The Control Charts should

used as a dynamic tool and should be prepared as a concurrent exercise as the work procee

The charts should be constantly scanned to identify indication of any significant deviation

quality and initiate the remedial action promptly.

Useful guidelines on control charts for concrete are given in ACI 214-77

“Recommended Practice for Evaluation of Strength Test Results of Concrete”. IS: 397 (Partto III) also cover control charts for general and special applications in industrial production

The charts are based on compressive strengths of cement and concrete test specime

Control charts for cement strengths are for different test ages (i.e. 3, 7 and 28 days) and a

both for strengths of individual test and moving average of five tests over periods of tim

Control charts for concrete and cement strengths are constructed in similar manner.

In addition to the incoming test data, the control charts also incorporate cert

reference lines constituting a framework within which the degree of control actually achiev

is assessed and remedial measures initiated where called for. The reference lines are term

the “Warning” and “Action” Limits. These limits provide feed-back for timely remedmeasures.

Preparation of control charts for cement & concrete is illustrated as under: -

12.1 CONTROL CHARTS FOR CONCRETE STRENGTHS

1. Control Charts

An illustrative set of compressive strength data (hypothetical data) and its furth

analysis for incorporation in a typical set of control charts is shown in Table A.

It is assumed that 3 companion specimen samples (a, b and c) are made from ea

homogeneous batch and constitute a “test”. Thirty such tests are covered in this Table.

One master chart incorporating all the raw data and three supplemental scatter cha

for closer scrutiny of i) the Central tendency, ii) ‘Within-test’ and iii) ‘Between-test’ scatter discussed. The data used is hypothetical and for illustrative purpose only.




Location

on x-

axis of

chart

Strength of individual

companion

specimens

Test

value

’T’(mean

of a, b

& c)

Moving

average

of ‘T’(five

tests)

Within-test

range

Between-test (or

batch to batch) range

a b c Range R

of a , b, c

Moving

average

RangeR (Ten

tests)

Moving

Range

R (Fivetests)

Moving

average

Range(Five

ranges)

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

1. 191 193 195 193 - 4 - - -

2. 181 185 186 184 - 5 - - -

3. 183 188 187 186 - 5 - - -

4. 198 195 192 195 - 6 - - -

5. 166 173 171 170 185.6 7 - 25 -

6. 177 176 172 175 182.0 5 - 20 -

7. 150 146 148 148 174.8 4 - 47 -

8. 187 191 192 190 175.6 5 - 47 -9. 214 211 211 212 179.0 3 - 64 40.6

10. 212 217 216 215 188.0 5 4.9 67 49.0

11. 232 231 227 230 199.0 5 5.0 82 61.4

12. 218 218 224 220 213.4 6 5.1 40 60.0

13. 192 194 190 192 213.8 4 5.0 38 58.2

14. 181 182 177 180 207.4 5 4.9 50 55.4

15. 190 192 194 192 202.8 4 4.6 50 52.0

16. 198 199 194 197 196.2 5 4.6 40 43.6

17. 197 197 200 198 191.8 3 4.5 18 39.2

18. 180 183 183 182 189.8 3 4.3 18 35.219. 190 191 195 192 192.2 5 4.5 16 28.4

20. 197 198 190 195 192.8 8 4.8 16 21.6

21. 187 189 194 190 191.4 7 5.0 16 16.8

22. 197 188 191 192 190.2 9 5.3 13 15.8

23. 240 244 236 240 201.8 8 5.7 50 22.2

24. 208 208 214 210 205.4 6 5.8 50 29.0

25. 155 150 151 152 196.8 5 5.9 88 43.4

26. 152 147 145 148 188.4 7 6.1 92 58.6

27. 168 166 161 165 183.0 7 6.5 92 74.4

28. 193 198 200 197 174.4 7 6.9 62 76.8

29. 222 214 215 217 175.8 8 7.2 69 80.630. 187 188 195 190 183.4 8 7.2 69 76.8

i)

Master Chart

The x-axis indicates the chronological order of tests (col. 1 of the Table). Strengths of

the individual companion specimens constituting a given “test” (Cols. 2 to 4), are plotted oneabove the other along the ordinate and their mean values (col. 5) representing each “test” arejoined to generate the Chart.




ii)

Moving-average strength Chart

As the relatively wide variations in the individual ‘test’ values tend to mask the centtendency, each test value is averaged with a certain number of previous tests (4 in this c

making a total of 5) and this “moving average”, viz. average of 5 consecutive tests (col. 6)plotted.

iii)

Within-test Moving-average Range Chart

In order to monitor the variation introduced by the testing technique itself, the mov

average of a certain number of ranges (10 in this case), exhibited by each of the sets o

companion specimens (col. 7), worked out under col. 8 are plotted in this chart. The ran

between the maximum 5 consecutive tests, as shown in Col. 7 is also plotted.

iv)

Between-test Moving-average Range Chart

This chart monitors the overall batch to batch variation of the production. It shows

moving average (col. 10) of a certain number of ranges (5 in this case) exhibited by a giv

number of consecutive tests (again 5 in this case), as shown under col.9.

It should be noted that other combinations of the number of companion specimens a

the number of values used for determining the moving averages, etc. can be treated in t

same manner. Each test may represent daily or shift-wise work.

2.

Control Limits

a)

For use in Master chart

The target average strength (TAV) and control limits can be estimated depending

the percentage of random test values permitt ed to fall below the specified or “characteriststrength (fsp) in terms of the standard deviation (d) or coefficient of variation (C

corresponding to the degree of control aimed at. These are tabulated below for use in

master chart.

No. of tests permitted to

fall below specified

strength (fsp)

Target average

strength

‘X’ (TAV)

Lower control limits Uppe

limits

(optionWarning Limit Action Limit

5% Fsp+1.65d or fsp/1-

1.65Cv/100

fsp X-3d or

X(1-3Cv/100)

Symmetricall

placed above tar

average line

20% Fsp+0.84d or fsp/1-0.84Cv/100

fsp X-3d orX(1-3Cv/100)

It should be noted that permissible low values up to 5% are applicable to concr

tests acceptance criteria as per IS: 456-2000 as well as to the cement tests wher

permissible low values up to 20% are applicable to mass concrete tests.




b)

For use in Moving Average Strength chart

The target value would be the same as tabulated above, but for control limit, d is

replaced by d/√n, where n is the number of tests considered for calculating the movingaverages.

c) For use in Moving Average Range chart

Upper and lower control limits can be worked out, if needed but these are not

symmetrically located above the target average line. Only the target average range values

corresponding to the standard deviation (d) or coefficient of variation (Cv) aimed at, are

usually incorporated. Their computation is somewhat more complex.

Target average range = β d or β X Cv/100

Where, X = Target average strength as estimated earlier

β = The coefficient depending on the number of companion specimens for within-test

control or the number of tests considered for obtaining the range in the case of between-test

control and not the number of ranges considered for obtaining their moving average.

Coefficients of variation (Cv) to be used for estimation of the target average range are given

below:

Sr. No. Variation being monitored Cv used for control

1. Within-test variations under

closely controlled laboratory

conditions.

2-3%

2. Within-test variations under well

controlled site conditions.

5-6%

3. Between-test i.e. batch to batchvariation in cement strength.

As mutually agreed by supplier and consumer,but not more than 8%.

4. Between-test i.e. batch to batch

variation in concrete strength.

As envisaged for the mix design depending on

the anticipated degree of control at site.

3. Target average strength (TAV):

TAV is worked out as: -

i)

fsp + 0.84 d for mass concrete.

ii) fsp + 1.65 d for structural concrete conforming to IS : 456

(Standard deviation d 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 d.

Then Cv = 15%= d/160+0.84d

Solving, d = 27.5 kg/cm2




Target av. Strength (TAV)

= 160 + 0.84 x 27.5 i.e. [fsp + 0.84 d]

= 183 kg/cm2

Upper warning limit (UWL) = 183 + 0.84 d i.e. TAV+0.84 d

= 206 kg / cm2

Lower warning limit (LWL) = 160 kg/cm2 i.e. fsp

Upper action limit (UAL) = 183 + 3 x 27.5 i.e. TAV + 3d

= 265 kg / 27.5

Lower action limit (LAL) = 183 - 3 d i.e. TAV – 3d

= 101 kg / cm2

The control chart for individual 28-day strength of mass concrete, incorporating th

limits is exhibited in plate IA.

CONTROL CHART FOR 28 DAYS STRENGTH OF

MASS CONCRETE - INDIVIDUAL TESTS

1

90

100

160

180

10

200

250

280

20 30

265

206

101 C O M P R E S S I V E S T R E N G T H K g

/ c m 2

SEQUENTIAL DATE STARTING

Designed TAV = Fsp+0.84d183

fsp = Lower warning Limit

TAV + 0.84d Upper warning Limi

TAV + 3d = Upper Action Lim

TAV – 3d = Lower Action Limit

Chart not to exact scale

PLATE IA

For moving average of 5 tests, the construction of control chart starts with T

decided as above for individual tests i.e. 183 kg/cm2 for mass concrete at 28 days.




The upper and lower warning limits are:

183+- 0.84 x 27.5 /√5 i.e. 220 & 146 kg / cm2 respectively.

The control chart incorporating these limits is exhibited in plate IB.

The lower action limit (LAL) shall, in no case, be lower than the absolute minimum

strength wherever specified. IS: 456 specifies on over riding absolute minimum of 0.8 times

the characteristic concrete strength.

CONTROL CHART FOR 28 DAYS STRENGTH OF

MASS CONCRETE – MOVING AVERAGE

1

120

160

180

10

280

20 30

C O M P R E S S I V E S T R E N G T H K g / c m 2


Designed TAV183

TAV –

(0.84d 5) = Lower warning Limit

TAV +( 0.84d 5 ) =Upper W.L.

TAV + (3d 5 ) = Upper Action Limit

Lo wer Action Limit = TA V – 3d 5


PLATE IB

140

240

173

220

193

146

13.2 CONTROL CHARTS FOR CEMENT STRENGTHS

Control charts for cement strengths should be for different test ages i.e. 3, 7& 28 days

and both for strengths of individual tests as well as for moving average of 5 tests.

i) For the control chart of strength results of individual tests, designed TAV should be as

mutually agreed between the supplier and the project, essentially based on past

records.

For example, let us assume that target average 7-day strength of cement for a

particular work from a particular plant is agreed to be 400 kg/cm2. The control limits (WL &

AL) should be decided on the basis of standard deviation (d) or coefficient of variation (Cv) asmutually agreed

on the basis of past records, but Cv should not be greater than 8%.

Suppose, in the above example, a Cv of 5% is agreed, then standard deviation is 400 x

5% = 20 kg/cm2.




The upper and lower warning limits are set as,

400 +- 1.65 x 20 i.e. (TAV+- 1.65d) i.e. 433 and 367 kg/cm2 respectively.

The upper and lower action limits are set as,

400+- 3x20 i.e. (TAV+- 3d) i.e. 460 and 340 kg/cm2 respectively.

The LAL (Lower Action Limit) should in no case be lower than the minimum specifi

strength as per IS: 269 or IS:1409 [220 kg/cm2 at 7 days].

Such a control chart for strength of individual tests of cement is shown in plate 2A.

CONTROL CHART FOR 7 DAYS CEMENT STRENGTH

- INDIVIDUAL TESTS

1

320

367

10

480

20 30

460

433

340 C O M P R

E S S I V E S T R E N G T H K g / c m 2


Designed TAV400

TAV - 1.65d = Lower warning Limit

TAV + 1.65d Upper warning Limit

TAV + 3d = Upper Action Limit

TAV – 3d = Lower Action Limit


PLATE 2A

ii)

For the control chart of moving average of 5 cement samples, the upper and lowwarning limits are set as,

400+- 1.65x20/√5 i.e. (TAV+- 1.65d/√5) i.e. 415 and 385 kg/cm2 respectively.

The upper and lower action limits are set as,

400+- 3x20/ √5 i.e. (TAV+- 3d/ √5) i.e. 427 and 373 kg/cm2 respectively.




Such a typical chart is shown in plate 2B

Acceptable level of variability of cement

The variability characteristics of cement as received in different consignments can be

related to the control charts as described above.

The cement content in the same batch of concrete mix as assessed by the observation

of the batch or from the automatic records shall be within 1.5% of the specified value.

If the cement content is assessed by the analysis of fresh concrete, it shall be within +-

8% of the specified value.

So far as the compliance requirements for the various other properties of concrete and

concrete materials are concerned, the same will be governed by the provisions in therelevant Indian Standards or the specifications laid down in the contract documents,

wherever the later override.

13.3 SOME USEFUL RELATIONSHIPS

STANDARD DEVIATION (I.S. 10262 - 1962)

The estimated standard deviation of given grade of concrete can be calculated from the

result of individual tests of concrete, using the formula:

S= √∑Δ2/n-1

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

N = number of samples test results.

If at least 30 test results for a particular grade of concrete at site with the same

materials and equipment are not available, the standard deviation, S, for the corresponding

degree of control, may be assumed from the following tabulation, given (IS: 10262 - 1982)




Table-I (Degree of Control)

Sr.

No.

Grade of Concrete Assumed Standard Deviation (S in N/mm2 )

Very Good Good Fair

1. M10 2.0 2.3 3.3

2. M15 2.5 3.5 4.5

3. M20 3.6 4.6 5.6

4. M25 4.3 5.3 6.3

5. M30 5.0 6.0 7.0

6. M35 6.3 6.3 7.3

7. M40 6.6 6.6 7.6

Degree of Field Control (as per I.S. 10262 - 1982)

Degree of Control Condition of Production

Very Good: - Fresh cement from single source and regular tests, weigh- batching of

materials, control of aggregate, grading and moisture content, contro

water added, frequent supervision, regular workability and strengtests, and good field laboratory facilities.

Good: - Carefully stored cement and periodic tests; weigh-batching of

materials, controlled water, graded aggregate, occasional grading a

moisture tests; periodic check of workability and strength; intermitte

supervision, and experienced workers.

Fair: - Proper storage of cement; volume batching of all aggregates, allowing

bulking of sand: weigh-batching of cement; water content controlled

inspection of mix, and occasional supervision and tests.

Acceptance Criteria (As per IS: 456 - 2000)

COMPRESSIVE STRENGTH

The concrete shall be deemed to comply with the strength requirements when both

following conditions are met:

The mean strength determined from any group of four consecutive test resu

complies with the appropriate limits in col. 2 of Table I.

Any individual test result complied with the appropriate limits in col 3 of Table-I.

FLEXURAL STRENGTH

When both the following conditions are met, the concrete is complied with tspecified flexural strength.

The mean strength determined from any group of four consecutive test results excee

the specified characteristics strength by at least 0.3 N/mm2

The strength determined from any test result is not less than the specif

characteristic strength less 0.3 N/mm2.




Specified

grade

Mean of the group of 4 non-overlapping consecutive test

results in N/mm2

Individual test

results in N/mm2

M15 > fck + 0.825 x established standard deviation (rounded off

to nearest 0.5 N/mm2) or > fck + 3 N/mm2 whichever is

greater

> fck - 3 N/mm2

M 20 or

above

> fck + 0.825 x established standard deviation (rounded off

to nearest 0.5 N/mm2) or > fck + 4 N/mm2 whichever isgreater

> fck - 4 N/mm2

NOTE: - In the absence of established value of standard deviation; the values given in 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.

INSPECTION OF STRUCTURES

Immediately after stripping the formwork, all concrete should 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 and/or load test may be carried out.




CHAPTER XIV

COMPILATION OF QUALITY CONTROL DATA

& INFORMATION SYSTEM

14.1 Data, Information & Information system

The data are the facts that have been obtained by measurement or observation or t

results and subsequently have been documented.

Data are used as basic input for processing through reasoning or calculation or bo

Data becomes information when they have been put through this conversion process

Information to be useful to the user must be helpful in discharging the responsibil

assigned to him.

The information system in the present context is collection of data, processing it a

then communicating the data relating to quality which would support decision-mak

by providing accurate and relevant information at the appropriate time.

Communication is an essential and most important part of the information system. Inot complete unless it engenders a response from the person to whom it is directed.

QC/QA system can be successful only if good communication exists between all t

involved parties and when adequate, relevant and high quality information is pass

throughout the whole of management system.

To look after documentation and information system, a separate focal official should

identified who will be responsible for storage, retrieval and safe custody of all t

documents generated through tests and inspections and also for processing of data.

14.2 Responsibility Chart

The duties of each of the members with respect to their contribution to the collecti

storage and retrieval of information should be clearly defined.

Each official who has been assigned responsibility for inspection or testing of mater

shall be responsible for submitting related inspection or test report, as appropriate

his next level of authority.

A responsibility chart (typical chart shown below) will indicate the documentat

activity assigned to each official working in the QA/QC department and laboratories.

The official concerned shall also be responsible for the technical content and accura

as well as its legibility, retention and validity.

Records prepared by the concerned official should be signed or otherw

authenticated and dated by his immediate supervisor as well as by the head of the filaboratory.

A separate document should be created for holding information on non-conform

items/materials as well as for tracking the same.




D O C U M E N T I N G

ACTIVITY1.TEST REPORTS

2.INSPECTION REPORTS

3.MATERIALCERTIFICATION

4.STATISTICAL

EVALUATION

5.PERMANENT RECORD& RETRIEVAL

Legend

Documentation

$

Verification

@

Certification

* Approval

1

Safe Custody

SC

PERSONNEL

J O / J

E / R A

A E / A R O

D e

p u t y

M a n

a g e r

M

a n a g

e r

/ A R O S e n i o r

M a n a

g e r

/ R O

$

$

$

@

@

@

*SC 1

*SC

*SC

1

1

1$ @SC

$ SC

TYPICAL RESPONSIBILITY CHART

14.3 List of Documents-Check List

Each laboratory should hold the following documentation: -

QC procedures, QC manual and quality plan.

Technical records: Specifications, Contract documents, Inspection & Test procedures,

relevant standards & codes of practice.

Records of calibrations of measuring and test equipment.

Mill certification.

Corrective action reports (CAR).

Material test reports.

Inspection reports.

Photographic/Video film records, particularly those of concreting and underground

portions of construction which may not remain accessible aftercompletion/commissioning of the project.

Non-conformance records.

Concrete Batching plant printout. Tracking reports.

Statistical evaluation reports.

Personnel qualification reports.

Audit reports.

Technical literatures & Manufacturers’ instructions.




Quality control data should be compiled on continuous basis and reports prepared

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

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

Index Plan.

Geologist’s reports de pending upon the nature of the project.

Note on foundation treatment, grouting pattern etc.

Nature of input materials like soil, cement, aggregates, steels and their source of supply

Test reports on input materials and acceptance criteria as laid in IS and other standard

Design of concrete mixes.

Summary of records and reports on grouting as specified in IS: 6066-1984.

Test reports on concrete like slump, compressive strength etc.

Control charts for cement and cement concrete i.e. Master charts, moving avera

strength and range charts etc.

Statement showing deployment of machinery.

Statement showing quality of concrete and earthwork executed and number of cube te

conducted.

14.4 Standardization of Records

The officials responsible for the Test record should document the following records: -

Data of test.

Area where the material is used.

Test method with reference to standards.

Test results.

Acceptance criteria.

Statement of compliance or non-compliance.

Remarks.

Testing personnel signature.

Signatures of immediate supervisor & head of laboratory.

Similar documentation should be followed for Inspection records.

14.5 Presentation of Information

To have uniformity in presentation and in order to provide a “check list”, it wouldnecessary to standardize suitable forms for testing of materials and for inspecti

Sufficient quantity of such forms should be made available at the laboratories by t

official responsible for procurement and stocking of all such forms.

Special attention should be given to the way in which the information can be presento the decision maker so that it may be assimilated in an efficient manner and in

precise format as possible. Control charts are one such presentation.

Visual displays on the control charts greatly enhance the communication

information. Control charts should be provided for all critical items including cu

tests, slumps, concrete temperature, air content and aggregate gradation.




14.6 Indexing of Records

An index should be established and maintained to identify and retrieve a specific

record or records by the designated individual. The indexing could follow a pattern suggested

herein below as an example: -

Example: -

Laboratory code ML Main laboratory

Function TST Testing

Task CEM Cement

Sub-Task PHY Physical

Calendar Year 10 2010

The code for a particular set of records may be written as ML/TST/CEM/PHY/10.

This is probably the first level of indexing; the number of secondary keys shall be

enhanced on computer.

14.7 Value of Information

Information must primarily possess characteristics of relevance, availability and

timeliness to have value and thus qualify as information.

Measures of value or quality of information are especially important in a quality

control system. Measures of quality are validity, accuracy and precision.

Even if information is presented in such a way as to be transmitted efficiently and

interpreted correctly, it may not be used effectively. In fact, quality of information is

determined as to how it motivates human action and contributes to effective decision

making.

Information may be evaluated in terms of utilities which may facilitate or retard its

use. These utilities are given below: -

1. Form Utility: - If the form of information matches more closely with the

requirements of the decision maker, its value increases e.g. if he is

looking for a graph depicting the history of concrete strength, he

appreciates receiving the data in a graphical form (control charts)

rather than in tabular form.

2. Time Utility: - Information has greater value to the decision maker if it is

available when needed. For each of the critical information, time

frame should be stipulated. One specific example is theinformation of non-conforming items reaching the focal official

for taking timely decision.

3. Place Utility: -

(Accessibility)

Information has a greater value if it can be assessed or delivered

easily. It is very important to have the information available at the

place desired. It is suggested to create focal position in each of the

laboratories to be responsible for retrieval of information.




14.8 Data Life Cycle

Data can have various stages in its own life-cycle namely: -

Data generation: at the laboratories in the form of test and inspection reports.

Data storage: the generated data is stored in the documents, microfilms, electromedia etc. in a suitable form before it is operated upon.

Retrieving the data: the stored data may have to be retrieved by searching out spec

elements from the medium in which it was stored.

Reproduction of data: the retrieved data may be converted or reproduced to

presentation format by way of reports, charts etc.

Interpretation of data: sometimes, the data may be synthesized to give a meaning

interpretation such as, summary reports, trend reports and exception reports etc.

Destruction of data: It is necessary to identify data in the context of its ‘useful li

which may be designated as 5 years, 10 years or archival. Destruction of data is t

terminal stage of the life cycle.

14.9 Data Processing

Data processing can be done in a variety of ways, ranging from basic manual devic

like registers, index cards etc. to Electronic Data Processing (EDP) using compu

hard ware & soft ware.

The vast amount of data handling connected with storage, processing and retrieval

information can be conveniently done through computerized system witho

intermittent human intervention.

Advances in communication technology have made it possible to exchange informat

through computerized system on real-time basis. Integrating these facilities into

cohesive environment would provide a low cost, effective, time-saving and automatQC system.

Despite the fact that computer is an efficient tool for processing data, the vital eleme

in an information system is the human one; it is the managerial talent that designs a

operates a successful QC system.

While designing the computerized information system, it may be necessary to inclu

the following features;

The system should be user friendly so that personnel with little knowledgecomputers can also operate.

The system should be flexible to cater to relevant changes in methodologies achanged parameters.

Validation of input data, wherever possible to ensure correctness of data.

Production of required management information system reports, routine reports et Alerting the users to exceptional conditions.

Data security through password feature for access to data base files and conducting required operations on the data base.




14.10 Movement of test reports

The chart showing movement of test reports including documentation and record is given

below: -

Movement of Reports



Himachal Pradesh


Part-II

Hydro Mechanical Works



Quality Assurance & Quality Control (HM Works) Page-1

CHAPTER – 1

INSPECTION OF INCOMING MATERIALS

AND PARTS OF HYDRAULIC STRUCTURES

Structural Steel & Stainless Steel

1.0 Scope:

This standard covers the requirement of steel plates, strips, sections, flats,

bars etc., for the use of structural works.

As per purchase order/Approved drawing the material inspection shall be carried

out.

1.1 References:

IS 961: Structural steel micro alloyed ( medium and high strength qualities)

IS 1852: Rolling cutting tolerance for hot rolled steel products

IS 2062: Steel for General structural purposes

IS 1608: Mechanical testing of metals

IS 1599: Method of Bend test

1.2 Freedom from defects:

All finished steel shall be well and cleanly rolled to the dimensions, sections

and weights specified. The finished material shall be free from cracks, surface flaws,

laminations, rough jagged and imperfect edges and all other harmful defects.

1.3 Chemical composition:See annex – 1

1.4 Selection and Preparation of Test Samples As per IS 1608.

1.5 Round test samples are permitted for above 28mm thickness. Bars below

28mm shall be tested without machining. Bars with thickness/diameter between

28mm and 71mm the bars may be symmetrically reduced by machining. For bars

above 71mm thickness/diameter the test samples shall be cut in such a manner

that deformation is avoided as far as possible. If shearing/flame cutting is employed

an adequate allowance shall be left for removal by machining. Before test samples

are detached full particulars regarding cast number, size and mass of plates, strips,flats and bars in each case shall be furnished.

1.6 Tensile Test

1.6.1 Number of tensile tests:




Bend test shall be made from finished steel for every 40t or part there of

rolled continuously, from each cast and for every class of product. For more than

one diameter/thickness of bar/section in processed, one additional tensile test shall

be made for each variation in 3mm diameter / 6mm thickness of the material

ordered.

1.6.2 Tensile test – See Annex.

1.7 Bend Test:

Bend test shall be made from finished steel from each cast, if mentioned in

purchase order. The number of tests for every 20t of material, or part of thereof,

rolled continuously. Test piece shall be cut length wise or cross wise for plates and

strips and length wise from sections, flats and bars, Rough edges may be removed

by filing/grinding.

1.7.1 Bend test – See Annex.

1.8 RETEST:

Should any one of the test pieces first selected fail to pass any of the tests

specified, two further samples shall be selected for testing in respect of each failure.

Should the test pieces from both these additional samples pass, the material

represented by the test samples shall be deemed to comply with the requirements

of that particular test. Should the test pieces from each of these additional sample

fail, the material represented by the test samples shall be considered as not having

compiled with the standard.

1.9 TOLERENCES:

1.9.1 BEAMS AND COLUMNS

Width

in mm

Toleran

ces

in mm

Depth

in mm

Tolera

n-ces

in mm

Width

in mm

Flange out

of Square /

out of

parallel

in mm

Depth

in mm

Off –

centre

web(in

mm)

maximu

m

0-100 2.0 0–200 2.0 0–

100

3.0 (max) 0 – 300

101–

125

2.5 201-

400

3.0 101–

250

30% of

flangewidth

(max).

301–

450

126–

250 4.0 401-

600 4.0 451–

600




Weight: Tolerance on weight per meter shall be + / - 2.5 % of the weight per meter

specified on the table (will be add afterwards)

1.9.2 Camber and sweep: Permissible limit is 0.2% of total length

Quality and out of square – It shall be 75% of total tolerance (plus and minus)

specified on the size.

1.9.3 Weight – the tolerances on the weight per meter for round and square bars

shall be the following %age of calculated weight per meter specified in IS 1732.

1.9.4 ROLLING TOLERANCES FOR FLATS

Width in mm Tolerances in mm Thickness in mm Tolerances in mm

0 - 50 1.0 Up & including 12 0.5

50 – 75 1.5

75 – 100 2.0 Over 12 4 % ( 1.5 mm)

Above 100 2% ( 6.0mm)

Weight – The tolerance on weight per meter shall be 5 % in the case of flats of

3mm in thickness and +5, -3 % for flats over 3mm in thickness of the weight per

meter specified in IS 1731.

1.9.5 ROLLING AND CUTTING TOLERANCE FOR PLATES

Length in mm Width in mm Thickness in mm Tolerances on Width in mm

Up to and

including

8000

Up to and

including

2000

Up to &

including 20

Over 20

- 0.0/ +10

- 0.0 / + 15

Up to and

including

8000

Over 2000 Up to &

including 20

Over 20

- 0.0 / + 0.5% of width

- 0.0 / 20mm

Over 8000 All Widths Up to &

including 8000

Over 20

- 0.0 / + 0.2 % of width

- 0.0 / +0.3 % of width

Size in mm Tolerance in mm

Over Up and including

--- 25 0.5

25 35 0.6

35 50 0.850 80 1.0

80 100 1.3

100 --- 1.6 % of dia / side width

Size in mm Tolerance in mm

Over Up and including

--- 10 7

10 16 5

16 --- 3




1.9.6 LENGTH

Length in mm Thickness in mm Tolerances on Width in mm

Up to and including

2200

Up to & including 20

Over 20

- 0.0/ 10

- 0.0 / 15

Over 2200 & including

3000


Over 20

- 0.0 / + 0.5%

- 0.0 / 15mm

Over 3000 & including

6300


Over 20

- 0.0 / + 0.5 %

- 0.0 / + 0.5 %Over 6300 and

including 8000


Over 20

- 0.0 / + 35

- 0.0 / + 0.5 %


Over 20

- 0.0 / 35

- 0.0 / 40

Thickness (Measure one point each at 1. Corners, 2. Middle of width, Middle of

Length)

Thickness in mm Tolerances on Width in mm

Less than 8 mm + 12.5 / -5.0

8mm to 12 mm ( including) + 7.5 / - 5.0

Over 12mm + 5.0 / - 5.0

Weight – shall not vary by more than +5 / - 2.5 % of theoretical weight.

1.10 INSPECTION OF UNDERSLUNG HOIST:

All the electrical and mechanical drawing of the under slung hoist shall be

approved by designs department.

TEST AT MANUFACTURE’S WORKS:

1. All electrical and mechanical equipments shall be t ested at manufacturer’s

works as per the bill of materials in the drawing.

2. The hoist shall be connected with control panel and pendent. The hoist shall be

fully assembled with motor, limit switches, brakes and pendent wiring through

cable ducts.

3. The hoist testing shall start with 70% safe working load. The motor current

shall be checked and shall be within 80% of the rated full load current of the

rated full load current of each motor. Normal speeds shall be achieved during

testing. The hoist shall be capable of lifting load from mid air.

4.

Test for the effectiveness of the automatic safety device to limit the upward anddownward travel of the hook.

5. Test for operation shall be conducted with safe working load. The motor current

shall be checked and shall be within the rated full load current of each motor at

safe working load. Normal speeds shall be achieved during full load tests. The

hoist shall be capable of lifting load from mid air.




The satisfactory operation of each controller, switch, contractor, relay and

other control devices and in particular the correct operation of all the limit

switches under the most unfavorable condition;

The correctness of all circuit and interlock and sequence of operation; and

The satisfactory operation of all protective devices.

6. Test for over loading shall be conducted with 125% of safe working load. During

the over load test, the hoist shall sustain the load under full control. The

specified speeds need not be attained, but the hoist shall show itself capable ofdealing with the over load without difficulty. Also the hoist shall be capable of

lifting the load from mid air.

7. The brakes shall be capable of holding the over load when the load is suspended

by the hook.

1.11 TEST CERTIFICATES:

The Test certificates for all motors, brakes, hook, wire rope, panel, shafts and

pins, and trolley wheel etc., shall be supplied by the manufacturer at the time of

testing. Maintenance and operator manual shall also be supplied.

1.12 DETAILS OF TESTING:

1. Over all dimensions

2. Head room

3. Hoist and long travel speed ( shall be within 10% of designed value) [ No load,

70% load, full load]

4. Operating currents for hoist and long travel ( No Load, 70% load, Full load)

5. Height of lift

6. Motor, brake and limit switch specification.

IS 1030

1.13 NON DESTRUCTIVE TESTS:

Non-destructive testing shall be applied if specified in the enquiry and order.

Under this heading are grouped the tests which aim at revealing defects cannot be

revealed by a simple visual examination, such as penetrant, magnetic particle,

ultrasonic, X-radiographic inspection; also including under this heading are tests on

the surface condition by visual or visual – tactile examination.

The Purchase order and enquiry shall specify:

1. The type of non–destructive testing which intends to carry out or to have carried

out;

2. The area and areas of the casting to which these tests apply, and the types of

discontinuity;

3. The severity level defining the acceptability of defects which may be revealed;

4. Whether the manufacturer is or is not responsible for carrying out the tests.

1.14 REPAIR OF CASTINGS:

Unless otherwise specified in the enquiry and order, castings may be

rectified by welding. All repairs by welding shall be carried out in accordance with

the procedure laid down in IS 5530: 1986.




If castings have been subjected to non – destructive testing by agreement, the

castings shall be re-examined in the area of repair following any rectifying

operation performed on the castings.

To form the basis of an agreement between the purchaser and supplier in this

aspect, the following classification shall apply concerning extent of repair:

1. Weld repair involving a depth not exceeding 20% of the wall thickness or 25mm,

whichever is less, shall be termed as minor repair.

2.

Any weld repair exceeding the above shall be termed as a major repair. Also anysingle repair having an area exceeding 250mm square for every mm of wall

thickness shall also be deemed to be a major repair, regardless of the

considerations mentioned in (1.) above.

1.15 CHEMICAL COMPOSITION:

The manufacturer shall carry out analysis from a sample of each melt of steel

and, if so specified by the purchase at the time of enquiry and order, shall supply a

test certificate of chemical analysis of the sample of steel for reach melt.

The permissible variation in product analysis from the limits specified shall be given

in IS6001.

1.16 TOLERANCES:

The purchaser shall specify the tolerances on all important dimensions. On

other dimensions, tolerances specified in IS4897 shall apply.

1.17 FREEDOM FROM DEFECTS:

All the castings shall be free from defects that will be adversely affect

machining and utility of castings. When necessary to remove risers or gates by

flame or a combination thereof, or by any other process is preferably done before

heat treatment.

In the event of any casting proving defective from foundry causes in the course ofpreparation, machining or erection, such castings may be rejected not withstanding

any previous certificate of satisfactory testing and / or inspection.

1.18 HEAT TREATMENT:

All Castings shall be heat – treated in a properly constructed furnace, having

adequate means of temperature control and the surface shall permit the whole

casting, being uniformly heated to the necessary temperature. All casting shall be

suitably heat- treated so as to attain suitable mechanical properties.

Unless otherwise specified at the time of enquiry and order or agreed between

manufacturer and Purchaser, all castings shall be carefully annealed or normalized

or normalized and tempered.

1.19 MECHANICAL PROPERTIES:

The mechanical properties specified are those which are to be obtained from

test bars cast either separately from or attached to the castings which they refer.

The test values so exhibited, therefore represent the quality of steel from which the

castings have been poured; then do not represent properties of castings themselves.




The minimum tensile strength, yield stress and elongation given in annex 1.

If so specified in the enquiry and order the bend test shall be carried out.

The test pieces shall be capable of being bent cold without fracture to an angle

mentioned in the table round a mandrel of 50mm.

1.20 INSPECTION OF BOUGHTOUT ITEMS:

1.20.1 Reduction Unit:

Following aspects are to be checked while inspection.

1. Size

2. Type

3. Ratio

4. Input HP & Speed

5. Output Torque

6. Shaft handling extended both sides LH, RH or dimensional limit specified.

7. Running test temperature of Oil & soundness Measurement.

8. Special conditions

a.

Efficiency if any

b. Self locking facility

c. Over all dimensions as per approved drawing

9. Main components : Material Tc and Heat treatment charts if any.

1.20.2 Wire Ropes IS 2266 – 2000:

Following aspects shall be considered

1. Diameter 2. Type of core 3. Lay

4. Galvanized / Un-galvanized 5. UTS 6. Breaking Load

7.

Any other special conditions

1.20.3 Plummer Blocks:

1. Type 2. Make 3. Dimensional check

4. Solid Base / Hallow Base 5. Material

1.20.4 Couplings:

1. Bore Dia. 2. Dimensional inspection 3. Material of the parts

1.20.5 Clutches:

1. Type 2. Hub diameter w.r.t. Shaft of motor/Gear box

1.20.6 Bearings:

1. Type Bearing 2. Dimensional Inspection

3. Type of Cage 4. Comparison of Static and dynamic capacity with charts available




1.20.7 Motors IS 325:

Following aspects are to be checked

1. HP (KW rating) 2. RPM 3. Mounting type

4. Shaft Extension 5. Terminal box position 6. Insulation Type

7. Voltage rating 8. IP Protection 9. Duty factor cooling

system

10.

Name plate ratingdetails 11.

Special conditions if any 12.

Over all finishing & outlook

1.20.8 Brakes:

A. Electro Magnetic Brake Hand release

B. Thruster Hand release

C. DC Brakes

1. Size of Brake

2. Rating capacity

3. Coil voltage etc.,

1.20.9 PVC Insulated Cables:

A. PVC Insulated armored cables IS

1554.

B.

Elastomer Insulated cables IS 9968C. PVC Insulated flexible cables IS 694

1. Size

2. Diameter

3.

Make4. Continuity check

1.20.10 Control Panels:

1. Operational check 2. Make

1.20.11 References – IS Codes:

1. IS 2062 - 2006 Structural Steel

2. IS 2004 - 1991 Forged Steel

3.

IS 1030 - 1989 Cast Steel

4. IS 2707 - 1996 Carbon Cast Steel

5. IS 318 - 1981 Leaded tin bronze

6. IS 305 – 1981 Aluminum Bronze

7. IS 6911 – 1992 Stainless Steel

8. IS 4622 – 2003 Vertical Lift Gates

9. 9. IS 1608 – 1972 for Mechanical Test Sample

10. 10. IS 7718 – 1991 Inspection of Vertical and slide gates

11. 11. IS 10096 – 1992 Inspection of Radial Gates and Rope drum hoists




1.20.12 Quality Assurance plan for Manufacture, Installation and Commissioning of hydraulic gates and handling equipments

Agreement

No:_________

Gate No :

________

Dated :

_________

S.No Component CharacteristicsContract

clauseType of

checkQuantityof check

Ref.document

AcceptanceNorm

Format

orRecord Agency

Remarks1 Rem

1

RAW

MATERIALS

1.1

Hot rolled

plates,section

and RolledRounds

Physicalproperties VMTC 1 for batch

Co-relation

ofTC IS : 2062

MTC orIR MQC

Reviewed

byDQC

Reviconq

thirQC

1.2Chemical

Properties do do do do do do do

1.3

Dimensional

Check Msrmt. Random/Full IS : 1852 IS : 1852 IR do do

1.4

Ultrasonic

Check for UT Ex. 100% IS : 3664 Level III IR do

Witnessed

by

Laminations IS:3664 PQC

Note : Heat numbers of plates may be recorded for co-relating the T.C.

2

CAST Steel -

Items.

2.1

Guide Roller

Assy.

& trunnion

assy

Physical

properties

Mech. Test

with test

bar 1 per heat IS - 1030 IS - 1030 TC MQC

Reviewed

and

witnessed

by

DQC

Revi

conq

T

2.2

Chemical

properties Chemical do do do do do do

analysis

2.3 Heat treatment Verification do do do HC do do

Ht. chart

2.4 Dimensions Msrmt. 100% do do IR do do

2.5 U T testing UT Ex. do IS : 3664 IS : 3664 do do do

2.6 Hardness Hardness

As specified

In App Drg App.Drg Tolerance 10 do do do




S.

No Component Characteristics

Contract

clause

Type of

check

Qualityof

check

Ref.

document

Acceptance

Norm

Formator

Record Agency

Remarks

1

Remar

2

3 FORGINGS

3.1 Shafts

Physical

properties VMTC

Entire

Lot IS : 1608 IS : 2004 or MTC MQC

Reviewed

by

Review

and

Pins etc. IS : 1875 DQC

conquer

by TQ

3.2

Chemical

properties do do IS : 2004 do MTC do do do

3.3 Bend test do do do do do do do do

3.4 Heat treatment HC do do do do do do do

3.5 Dimensions Msrmt. 100% App.Drg

No

significantdefect IR do do do

4

STAINLESS

STEEL

4.1Plates for Seal

SeatsPhysical

properties VTC 100%

IS: 1570

PartVIS : 6911

IS: 1570

PartVIS : 6911 TC MQC

Reviewedby

DQC

Review

andconque

by

TQCand pins for

rollers

4.2

Chemical

properties do do do do do do do do

4.3 Hardness Msrmt. do do do IR do do do

4.4 Dimensions do do do do do do do do

4.5 Surface defects Visual do App.Drg App.Drg TR do do do

inspection

4.6U.T. tests for

internal UT test do IS : 3664 Level III IR do do do

defects IS : 3664

Remarks

1

Remar

2




S.No Component Characteristics

Contract

clause

Type of

check

Quality

of

check Ref. document

Acceptance

Norm

Format

or

Record Agenc

5 RUBBER

5.1 Rubber Seals Physical properties

i) Hardness after VTC

Random

one IS : 11855 IS : 11885 TC or IR MQC

valcanisingfor

batch

ii)Elongation do do do do do do

iii) Tensile strength do do do do do do

iv) Water

absorption test do do do do do do

v) Dimensions Msrmt. 100% App.Drg App.Drg IR do

Note : Only moulded seals are to be used and no extrution seals are to be accepted

6 BOUGHT OUTS

6.1Bolts and

Nuts Hardware items VTC Random App.Drg App.Drg TC MQC

Bearings etc.

6.2Specification and

make do do do do do do

6.3 Dimensional check Msrmt. do do do IR do

6.4 Physical properties VTC do IS : 1367 IS : 1367 TC do

6.5

Chemical

properties do do do do do Do




S.N

o Component Characteristics

Contract

clause

Type of

check

Quality

of check

Ref.

document

Acceptance

Norm

Formator

Record Agency Remarks 1 Remark

7 WELDING

7.1 Fillet welds

Weld procedure

for fillet Verification Random WPS IS - 3658 IR MQC

Reviewed

or

Review

and

and butt

welds and butt welds

of

document IS - 3664

Witnessed

by

conquer

by

DQC TQC

7.2

Qualification of

welders do Random WQR IS - 7318 do do do

7.3

Quality of fillet

welds Visual Random IS - 3658

No

significant do do Reviewed by do

defectspurchase

Rep.

7.4

Quality of butt

welds.Butt D.P 100% Level iii

weld 6 mm

plates and U.T 10% IS - 3664 IS - 3664 do do do do

up to 20 mm. R.T IS - 3657No

significant do do do do

defects

8FABRICATION

OF

GATE PARTS

Dimensionalinspection Msrmt. Each App. Drg. App. Drg. IR MQC

Reviewedand

Reviewand

Witnessed

DQC

conquer

by TQC

8.1 Skin plateAssy. do do do do 2mm do do do do

8.2

Horizontal

girders d0 do do do 2mm do do do do

8.3

Arms

Assembly do do do do 2mm do do do do

LH + RH

8.4Tie between

trunions do do do do 2mm do do do do

8.5

Trunion

Assembly do do do do 1mm do do do do




S.N

o Component Characteristics

Contract

clause

Type of

check

Quality

of check

Ref.

document

Acceptance

Norm

Formator

Record Agency Remarks 1 Remark

9

EMBEDDED

PARTS

9.1

Welding of

tie flats LH Msrmt. Each App. Drg. App. Drg. IR MQC Reviewed by

Review

and

with butt

weld DQC

conquer

by TQC

Welding oftie flats RH do do do 2mm do do do do

with buttweld

9.2 Welding oftie flats to LH - Top do do do 2mm do do do do

Yoke girder

web LH - Bottom

9.3 do RH - Top do do do 1mm do do do do

RH - Bottom

Note : 1. Each existing gate vent wise dimensions are to be measured prior to fabrication of the tie flats.

The weld is to be carried out with butt weld 100% X - Ray and after Quality Check the band stress relieved.

2.After tie flats are made alright the yoke girder web to tie f lats weld is to be done with required size of fillet weld and checked with DPI to ensure frfrom cracks. A record is to be maintained gate wise.

10 PAINTING

10.1 GatesSurface

preparation Visual Random App. Drg.App.Drg. IR MQC

Witnessedby

Reviewand

Tech spn Tech spn DQC

conquer

by

TQC10.2 Primer coat do do do do do do do do

10.3

Intermediate

coat do do do do do do do do

10.4 Finish coat do do do do do do do do

10.5

Thickness of

paint Msrmt. do do do do do do do




S.

No

Componen

t

Characteristic

s

Contrac

t

clause

Type of

check

Qualit

y

of

check

Ref.

documen

t

Acceptanc

e

Norm

Forma

t or

Recor

d

Agenc

y

Remarks

1

Remar

2

11.

1

Check for

critical

dimensions Msrmt. Each

App. Drg.

Tech spn

App. Drg.

Tech spn IR MQC

Witnesse

d by

DQC

Review

and

conque

d by

TQC

11.

2

Balancing of

gate

Verificatio

n do do do do do do do

11.

3 Dry test Visual do do do do do do do

11.

4

Wet test /

leakage test Visual do do do do do do do

11.

5

Static head

load test do do do do do do do do




1.20.13 List of Abbreviation :

1 V Verification 9 RT Radio Graphic Test

2 VMTC

Verification

of Material

Test

Certificate 10 Appd.Drg Approved Drawings

3 TC

Test

Certificate 11 VTC Verification of Test Certificate.

4 HC Heat Chart 12 Msrmt Measurement

5 IRInspection

Report 13 WQR Welders Qualification Record

6 MTC

Material

Test

Certificate 14 WPS Weld Procedure Specification

7 UT

Ultrasonic

Testing 15 MQC Manufacturer Quality Control

8 DP

Die

Penetrating

Test 16 DQC Department Quality Control

17 TQC Third Party Quality Control

Note : .1. The above procedure is the model to be adopted. The manufacturer shall prepare detailed QC assurance plan based

on their experiences and concurence of engineer's incharge is to be obtained before starting the activity.

2. The Gate wise QC records are to be maintained and obtaining TQC concurence 5 copies of each document is to

furnished for record and final acceptence.

Manufacturee QC

Department

QC Third Party QC




1.20.14 Steel Plates for Penstock

Pressure Vessel quality Steel plates or the equivalent are normally used for the

fabrication of Penstock and its specials/accessories. Each steel plate shall be ultrasonically

tested as per ASTM-A-578 and should be free from indentation, projection, roll marks or

any other defects.

Additional requirement for ASTM quality steel plates

i)

Permissible variation under & above in specified width and length shall be in

accordance with ASTM-A-20 M

ii) Negative tolerance on thickness shall not be acceptable; whereas positive tolerance in

thickness shall be as per ASTM-A-20 M.

iii) Marking shall be made on each steel plate, indicating thereon, name or brand of the

manufacturer, heat and slab number, specification number and grade, class,

dimensions, weight and type etc, in accordance with ASTM-A-20-M

iv) Marking shall be done by steel die stamping and/or by stenciling.

v) Edges of each steel plate shall be sheared from all four sides.

vi) Tolerance in squareness shall be ensured to the maximum accuracy. The diagonal

difference will not exceed 1% of the nominal width.vii) Necessary test certificates or photo copies thereof relating to mechanical properties,

chemical composition, ultrasonic testing and heat treatment temperature etc. of steel

plates supplied shall be furnished by the supplier for each plate/heat before the actual

shipment. Various tests shall be carried out in accordance with the requirements of

ASTM-A-20-M and other relevant ASTM standards.

1.20.15 Inspection of Steel Plates

Steel plates to be used shall be duly inspected either by Mills authorized

Inspector or by a third party. However, such inspection shall also be witnessed by the

representative(s) of the Purchaser.




CHAPTER – 2

WELDING DETAILS

For Hydraulic gates manufacture

2.0 Welding processes are mainly three viz, metal arc welding, Gas and submerged

welding, and submerged arc welding. Each provides a means of melting the metal at

the joint to be welded and generally, a means of adding additional metal to the joint.

This paper discusses in general the welding and related processes for the

installation of anchors and other embedded metal parts gate leaf for the hydraulic

gates and its handling equipment.

Most widely used process throughout most industries is metal are welding. Nearly

all metals, ferrous and non- ferrous can be welded. The main features of this process are as

follows:

Immediate heating.

Depth of fusion and heating is fixed by electrode type size and current and can be

controlled somewhat but not closely, by the operator.

Nearly all metals can be welded. Welding can be carried out in all positions.

Wide range of thickness can be welded.

2.1 Specification:

Welding shall be carried out in accordance with the specifications mentioned in some of the

codes:

IS – 813 – 1986: Scheme of symbols for welding

IS – 814 – 1981: Covered electrodes for metal are welding of structural steel.

IS – 816 – 1969: Code of practice for use of metal arc welding for general construction

in mild steel.

IS – 822 – 1970: Code of procedure for inspection of welds

IS – 9595 – 1996: Code of metal arc welding of carbon manganese steels

Some of the precautions to be borne in the mind while welding are

2.2 Preparation of Base Material:

The grooves may be prepared by machine flame cutting. All oil, grease, paint, loose

scale etc., shall be removed from the vicinity of the weld prior to welding. Notches or other

surface defects resulting from preparation shall be ground smooth before joint is welded.

Shearing of plates shall only be permitted on edges of secondary material which will

be welded all edges of primary material must be machine flame cut or if sheared, must beplanned to a depth of 6mm.

Material thicker than 40mm and up to 60mm shall be preheated to 65C before

flame cutting or welding.

Material thicker than 60mm shall be preheated to 104C before flame cutting and or

welding.




2.3 Assembly:

Assembly of gate parts shall be carried out as per the drawings. Wherever

temporary welds are used the same are to be removed and grounded wherever necessary.

If braces are required to support the flanges of girders during assembly and handling

temporary welds must not be used to attach the braces to the flanges.

2.4 Welding Processes:

The welding shall be carried out as per the code of practices of IS standards and the

methods finalized with the in house expertise.

The most widely used welding process in sites is shielded metal arc welding

(SMAW).

2.5 Weld Consumables:

2.5.1 Welding of Carbon steel to carbon steel:

E7018 low hydrogen electrodes, confirming to specification CSA W48.1 must be used.

2.5.2 Welding of Carbon Steel to stainless steel:

(IS 2062 to IS 1570 / 30Cr13)

E 308 – 16 or E 308L – 16 Stainless steel electrodes confirming to specification CSA 48.2

must be used. Alternatively E 309 – 16 or E 309 L – 16 stainless steel electrodes can be

used for Ni – 8 to 10 steel.

2.5.3 Welding of Stainless steel to cast steel:

E 308 – 16 or 308 L – 16 Stainless steel electrodes confirming to specification CSA W48.2must be used.

An electrode comparison chart is enclosed. The consumption of electrodes per

meter length for fillet and butt welds is also enclosed.

2.6 Storage of Electrodes:

All electrodes are to be handled as explained below:

All electrode containers arriving at the site shall be examined for damage. Damaged

containers shall be returned to the supplier.

Immediately upon opening each can of electrodes the contents shall be placed in a

holding oven held at a temperature of 90 to 120C

When electrodes have been out of the holding oven for a period of time exceeding 4

hours they shall be returned to the holding oven for a minimum soaking period of 4

hours before again being withdrawn.




a ) DOWN HEAD

b) V

c) H

d) O

2.7 Welding Position:

The different weld positions are shown in fig.1:

2.8 Nature of Current:

AC or DC current may be used. Since the welding current costs from a very small

proportion of the total costs of a welding job it is enough if data of current consumption are

given by means of standard values, which have been determined for definitely typical

welding conditions.

Some of standard values for current consumption per electrode are as below: -

Electrode type

Power Consumption per electrode (KWH)

Electrode length (mm)

350mm 450mm3 ¼ 4 5 3 ¼ 4 5

Citobest 0.106 ---- ---- ---- 0.204 0.304

Overcord 0.114 ---- ---- ---- 0.220 0.328

Overcord – S ---- ---- ---- 0.160 0.225 0.340

Overcord – SS ---- ---- ---- 0.194 0.292 0.460

Supercito ---- ---- ---- 0.158 0.240 0.372




2.9 Tack Welds:

Tack welds shall be made by qualified fitters, tackers, or welders and are subject to

the same quality and preheat requirements as final welds.

Tack welds shall be held to the minimum size necessary to hold the members in

proper orientation during welding but shall not be less than 40mm and more than 70mm

long.

Tack welds and temporary welds which are not incorporated into the final weld

shall be removed and the surface made flush with original surface.

2.10 Precautions for Quality welds:

Each bead and layer shall be thoroughly cleaned of all slag and spatter before the

next bead or layer is deposited.

Welds shall be free from cracks, tears and gross porosity. Defective welds shall be

removed by gauging, chipping or grinding and the joint re welded in accordance with the

specification. Where complete penetration welds are to b e welded from both sides, the

root of the first side welded shall be gauged to sound metal before the second side is

welded.

When welding in the vertical position, the progression shall be upwards for all passes.

2.11 Limitation of fillet weld: As per IS 9595: 1996

The fillet welds connecting parts, the fusion faces of which form an angle of more

than 128 or less than 60 should not be relied upon to transmit calculated loads at the full

working stresses unless permitted to do so by the standards of the particular application.

The design throat thickness of the flat or convex fillet weld connecting parts the

fusion faces of which form an angle between 60 and 120, may be derived by multiplying

the leg length by the approximate factor as follows:

2.11.1 Angle between fusion faces

in Degrees

Factor by which leg length is

multiplied to give designthroat thickness

60-90 0.70

91-100 0.65

101-106 0.60

107-113 0.55

114-120 0.50

Minimum sizes of fillet welds shall be as given below to avoid cracking.

2.11.2 Thickness of thicker part Size of fillet Weld

in mmOver in mm Up to and including in mm

---- 6 3

6 12 4

12 18 6

18 36 8

36 56 10

56 150 12

150 ---- 16




a l a

L

13 L (APPRO)

AA

A

SKIN PLATE

150 TO 180

B

100

100

60°

ALL BUTT WELDS ARE

FULL STRENGTH AND

100% X-RAY WELD

THICKNESS 8

TO 10MM

2.12 Joint locations of hydraulic gates:

For any fabrication getting full length plates and sections were difficult task and are

to be welded to form the desired length and size by metal arc welding. By joining two parts

by welding always have some deficiency though we take lot of precautions.

The joints are chosen at safe zones even in case of 90% efficiency of joint the desired

factor of safety can be achieved.

Some of the tips where the joints are proposed are as follows:.

2.12.1.1 Vertical lift Gates:

Joint in skin plate: Joints in skin plate are more important and hence full strength

butt welds of X-ray quality adopted / achieved.

The required skin plate size is to be made independently with available plates using

butt welds and after checking the welds layout is to be made from centre line of vent

marking on skin plate and proceed to either side to fix vertical stiffeners, girders

and end girder / End box.

As far as possible number of joints shall be minimized or eliminated.

2.12.1.2 Joints in Horizontal girders where ever possible: The joint in the horizontal girder shall be at 1/3 of span or near by with a variation

of 500 to 800mm because at this zone the shear and bending is moderate. No joint

is to be made at centre of span where max. bending moment occur.

No joint shall be provided in tension flange at point (A) and (B) for safety. This isbecause the project failed in our country is mostly due to the failure of this joint and

hence advised.

The joints in flange and web are to be staggered as shown

In assembly the welding joints in the girders are also staggered while welding.

Horizontal Girder




SKIN PLATE

E

H

2 0 0

500

LIFTING ARRANGEMENT

PADDING

1 3 5

HORIZONTAL GIRDER

2.12.1.3 Welding of horizontal girders to end vertical or end box:

The weld is more important to transfer the shear load from horizontal girder to end

box. Due to vibration under partial operation this weld generally develops cracks in a

span of 3 to 5 years operation. One is to be careful in doing this weld and also the welds

are to be checked during maintenance..

2.12.1.4 Lifting Arrangement:

Lifting arrangement is very important part in gate where in the total load

takes full load while lifting. Hence the load is to be transmitted for at least two

girders.

The weld strength shall be sufficient to take care of load under normal working

condition and also under break – down torque condition of motor loading.

The bracket is to be located over full depth stiffener as shown to avoid additional

bending on YY direction to horizontal girder.

For better performance the lifting bracket shall be fixed matching the C.G of the gate

duly checking the C. G of gate after completion of manufacture and assembly.

2.12.1.5 All other welds are also more important and continuous one to control the rus

The intermittent welds are to be avoided in hydraulic structures because at the points

where no weld corrosion is rusted and got damaged. In case if one wants to go for

intermittent weld the surface of matching plates at jointare to be machined and set one

over the other as required without gap to control the rusting.




STAGGERING SHALL

BE MIN 50MM

t

2

2

60°

t

2

2

60°

t

2

2

60°

Min 50 - 75mm

SKIN PLATE

VERTICAL TEE

2.12.2 Radial Gates:

2.12.2.1 Skin plate assembly with vertical stiffeners:

The fabricator must be aware about the joints to be proposed. For larger gates

the skin plate shall be made with vertical as well as horizontal joints and careshall be taken that joints ate to be staggered and crucify joints ( ┼ ) shall not be

used.

All welds welded in jig shall be prepared with D/S opening as shown.

All site welds shall be proposed with welding from U/S open to facilitate welding

after alignment with down hand position.

The skin plate joint is so located that there will be at-least 50 – 75 mm minimum

gap from Tee weld.




C L O F B O T T O M

H - G I R D E R

C L O F 2nd

H - G I R D E R

CL O F 3r d H - GI RDE R

S K I N

P L A T E S

FDESIGN

I D

E A L L O C A T O N F O R J O I N T

SF BM

If the horizontal joints are proposed in skin plate the joints in tees also should be

staggered as shown to improve the efficiency of system.

The location of horizontal joint is made where bending moment is less for safety.

No joint is provided at centre of span / support where max. bending moment

occurs




LC

A BC

LC OF ARM LC OF ARM

IDEAL LOCATION FOR JOINT

t

1

0 T O 1 2 T H K

60° SKIN PLATE

t

60°SEALING WELD AT SIDES AFTER

ASSEMBLY AND ALIGNMENT

SKIN PLATE

Where ever the X-ray or UT is not possible it is better to go for backing plate.

The thickness of backing plate may be up to 8mm to mm and width of plate may be

80 to 100 mm. Alternatively if the skin plate manufacture is carried out in shop assembly

the joint may be proposed as follows for easy assembly at site and sealing run is to be made

for leak proof .

Note: where ever shop assembly of skin plate care shall be exercised to get accurate vent

width in construction otherwise gate cannot be matched to suit the vent.

2.12.2.2 Horizontal girders:

For joining the required size of plate butt welds of full strength 100% X-ray quality

welds are to be provided. For bigger gates considering the material availability

handling facilities etc., one or two site joints are provided to suit the requirement..

For all practical purposes avoiding the site joint will be safest method. The

location of joint may be adopted at minimum bending moment zone and no joint

is to be provided at max. bending moment zone i.e., centre of the span.




BB

THE WELD MAY BE AVOIDED

AT BENDS FOR SAFETY

OTHER WISE ONE HAS TO

ENSURE THE JOINT IS 100%

FULL STRENGTH WELD.

FULL STRENGTH BUTT WELD

A

B

75 75

150

60°

30 30 1

0

1 0

ALL BUTT WELDS ARE

FULL STRENGTH AND

100% X-RAY QUALITY WELD

2 7 0

5 0

9 0

9 0

500

4 0 0

5 0

2 1 0

2 3 0

8 0 0

2 7 0

5 0

9 0

9 0

500

4 0 0

ELEVATION

10832

11300

B

B

A

A

61.6

200 200

400

350 350

12000

17.116°

234

8 0 0

61.6

200200

400

350

17.116°

234

TRUNNION LH TRUNNION RH

TIE BETWEEN

TRUNNION

TIE BETWEEN TRUNNION

The typical joint for Horizontal girder is as follows:

The other parts are to be welded joints with continue welds. And the sizes of weld maybe provided as per IS 9595.

2.12.2.3 Tie between trunnion:

The tie between trunnion is provided to take care of lateral loads as tensions

between trunnions,

No. of projects (Radial gates were failed on account of failure of Tie between welds.

The tie between trunnion is to be welded to cast steel trunnion.

The history speaks that these welds are developing cracks after few years of

operation. In some projects the weld provided is insufficient and there is no

record of weld inspection.

In some projects the welding has done only on top and no weld is provided at thebottom and sides. People are taking advantage if quality checks are not made. At

the same time one has to remember these structures have to withstand the

water loads.

By experience it is better to provide tie between trunnion to the gate size max.

15.0M X 10.0M and for bigger gates it is better to go for the thrust block, so that

the lateral load can be transferred directly to pier through bracket flange.




SEC-BB

50

6

165165

90 9075 75

5

4 7 5

50

6

2 7 0

5 0

9 0

9

0

500

4 0 0

11300

4 0 0

10802

5 0

2 1 0

2 3 0

DETAIL-A

17.116°

61.6

200 200

400

17.116°

234

The sequence of welding shall be as follows:

I.

First weld the center thick plate with low hydrogen electrode (7018).

II.

Weld the bottom flange to thicker plate.

III.

Trim the tie between trunnion length exact required and lower the same over bottom

flange keeping thicker plate in between as shown.

IV. Weld the tie to the trunnions as well as thicker plate.

V.

Weld middle stiffeners and flanges at top. VI. Periodic inspection is necessary.

Important: The radial gate with independent anchorages, the weld between tie flats

and yoke girder web and weld between trunnion flange and tie between trunnion

should be strong enough to avoid washing away of gate. Hence in these locations,

welds are more important to check during maintenance.

2.13 Welding Defects : Their Causes and Prevention

2.13.1 Welding Objectives:

The main objective is to obtain sound defect free welded joints.

Normal welds always contain minute slag inclusions or porosity as revealed in non –

destructive testing. Such small imperfections which cause some variations in the normal

average properties of the weld – metal are called discontinuities.

When discontinuity is large enough to affect the function of the joint, it is termed as

defect.




Defects are caused by:

Substandard welding

consumables.

Inefficient workman

ship.

Lack of cleanliness.

Un favorable properties of

the base metal.

Low ambient temperature and humid atmosphere.

Every fabricator must strive to prevent the occurrence of weld defects in the first

instance and to rectify them if they have occurred. Rectification welding defects increases

fabrication costs considerably.

2.13.2 Typical Defects which can occur in arc Welds:

2.13.2.1 Incomplete Penetrations: This defect occurs at the root of the joint when the

weld metal fails to reach it or weld metal fails to fuse completely with the root

faces of the joint. As a result, a void remains at the root zone which may contain

slag, inclusions. In a fillet weld, poor penetrations at the root zone can give rise

to cracking of single butt weld.

Incomplete penetration in a single Vee butt weld

In a weld adequate root penetration is ensured by using:

Correct size of electrode.

Sufficiently high current.

Directing the arc towards the root during deposition of the root pass.

Rectification of this defect is a very costly proposition because it requires

removal of the entire thickness of the weld and re welding.

2.13.2.2 Lack of Fusion:

LACK OF FUSION is defined as a condition where boundaries removal of the

entire thickness of the weld metal and base metal or between adjacent layers of

weld metal.

This defect is caused by the presence of:

Scale ((rusting)

Dirt

Oxide

Slag

Other non metallic substances which prevent the underlying metal from

reaching metallic temperature.

To prevent the occurrence of this defect, the following steps should be taken:

Keep the joint surface clean Use adequate welding current

De slag each weld pass thoroughly Place weld passes correctly next to

each other

Lack of fusion is rectified in the same way as lack of prevention.




2.13.2.3 Undercut: -

This defect appears as a continuous or dis - continuous groove at the

toes of weld pass and is located on the base metal.

Undercut in the vertical leg of a horizontal and vertical fillet weld.

It occurs prominently on the edge of a fillet weld deposited in the horizontal

position.

This defect is usually caused by:

Excessive welding current

Too high speed of arc travel

Wrong electrode angle or excessive side manipulation

Also causes due to damp or improperly formulated electrodes.

Note : In the case of statically loaded structures the presence of small and

intermittent under cutting will reduce fatigue endurance of the welded joint

and hence it should not be permitted.

Rectification :

The defect is rectified by filling up the undercut groove with weld pass. If

under cut is deep and contains slag, it should be clipped away before re welding. If

the rectification is carried out on thick joints and on high tensile seals, the welding

procedure including pre heating should correspond to the recommended procedure

for particular steel.

2.13.2.4 Overlap:

The defect occurs at the toes of weld and consists of weld – metal which has

over flowed on the base metal surface without actually fusing to later. It can be

isolated intermittent or continuous. It occurs more often in fillet welds and results

in an apparent increase in the weld size.

Cause:

It is occurred by an incorrect manipulation of the electrode, where by the

weld metal flows away from the fusion zone. Use of too large an electrode in relation to the welding position, and

excessive current coupled with a too low welding speed also promote its

occurrence.

When a single – pass fillet larger than 7.5mm in leg length is made in the

horizontal position, the molten metal tends to sag and causes overlapping in

at the toe of the horizontal member as shown in the figure.




Overlap in a horizontal-vertical fillet weld

Rectification: -

Slight and intermittent over lapping may be ignored in statically loaded

structures, but it should not be permitted in dynamically loaded structure as over

laps act as stress – raises, overlap is rectified by grinding, chipping or gouging out

the excess infused weld metal. Care should be taken to leave the smooth surface.

2.13.2.5 Slag Inclusions :

Non metallic particles of comparatively large size entrapped in the weld metal

are termed as slag inclusion.

Slag inclusions in a single-Vee butt weld

Slag inclusions are detected by the normal non destructive testing methods.

While non – metallic inclusions are observed in the weld micro structure at high

magnification.

Causes :

Slag inclusions usually occurs in multi pass weld due to imperfect cleaning of

the lag between the disposition of successive passes as shown in the figure. It

may also be caused by heavy mill scale, loose rust, dirt, grit and other substances

present on the surface of base metal. Slag trapped in under cuts or between unevenpreceding runs may give rise to elongated lines of included slag when a subsequent

weld pass is deposited.

The melting characteristic of the welding consumables and particularly the

viscosity of the rusting slag has an important bearing on inclusion. The molten slag

should float freely to the surface of the weld pool and easily removable on

solidification.

Prevention:

Use proper welding consumables.

Keep joint surfaces (especially gas cut surfaces) and bare filler wires perfectly

clean and clean the base metal thoroughly before welding.

Avoid under cuts and gaps between deposited perfectly clean and clean the base

metal thoroughly before welding.

Avoid under cuts and gaps between deposited passes.

Clean the slag thoroughly between weld passes.




The strength of welded joint may be considerably reduced if large irregular

inclusions or elongated lines of inclusions at the weld junction are present. These

sometimes give rise to radiating hair line cracks. The presence of small, isolated

globular inclusion may not however, seriously affect the static strength of a joint and

these may normally be disregarded.

Rectification:

The portions of weld metal which contain slag inclusions must be removed

and then filled with sound weld metal.2.13.2.6 Porosity:

The presence of a group of gas pores in a weld caused by the entrapment of

gas during solidification is termed as Porosity.

The pores are in the form of small spherical cavities either clustered

locally or scattered throughout the weld deposit. Sometimes entrapped gas gives

rise to single large cavity, which is termed as a blow hole. In some rarer cases,

elongated or tubular gas cavities are presented these are referred to as piping or

worm holes.

The gases are evolved by the chemical reactions in the welding are

these gases may have high solubility in the molten weld metal, but as the metal

solidifies and cools, their solubility decreases rapidly and they are revolved from the

metal, sometimes if the weld metal solidification and cooling is too rapid, the gas

gets entrapped in the form of Porosity.

Causes:

Chemically imperfect welding consumables for example deficient in deoxidizers

Faulty composition of the base metal or electrode wire for example, high sulphur

content.

Oil, grease moisture and mill scale on the joint surface.

Excessive moisture in the electrode coating or submerged – are flux.

Inadequate gas shielding or impure gas in a gas shielded process.

Low welding current or too long an arc.

Quick freezing of the weld deposit.

Puddling of the weld metal and use of preheat or higher current allow sufficient

time for the dissolved gases to escape from the weld metal. Presence of small, finally

dispersed porosity is normally not expected to affect the static and even dynamic

properties of a welded joint. However excessive porosity blow holes or piping must be

guarded against as they seriously impair these properties. Their presence is detected by

the conventional NDT methods. The defective portions must be removed and re-

welded.

2.13.2.7 Crack:

Crack is defined as a discontinuity caused by the tearing of the metal while in a

plastic condition (hot crack) or by fracturing of the metal when cold (cold crack). It

represents a failure under stress of a metal when it is behaving in a brittle manner i.e. it

is inclined to fracture without deformation.




3

2

1

4

5 6

7

8

Shrinkage stress

Shrinkage stress

Cracking can occur in the weld metal, at the fusion line or in the base metal. Cracks

may be classified according to location and direction of line and they may range in size

from large cracks which can be seen by the naked eye (called macro cracks) to

extremely small fissures which are detected with the aid of a microscope (called micro

cracks). Typical cracks occurring in welded joints are as shown.

2.13.2.7.1 Hot Cracks:

These cracks occur at temperatures above 540 C and when observed under the

microscope are seen to have traveled across the boundaries between the grains (intergranular). If the crack has extended to the surface, the fractured surface is found to be

coated with the blue scale or possibly black scale.

Classification of cracking according to location in a weldment :

1)

Weld metal crater cracking.2) Weld metal transverse cracking.

3) Base metal heat affected zone transverse cracking

4) Weld metal longitudinal cracking

5) Toe cracking

6) Underbead cracking

7) Fusion line cracking

8) Weld metal root cracking.

Hot cracking occurs in a solidifying metal at the end of the solidification

range, when this last portion is still liquid and the mass of the metal is unable to

deform without cracking. At this stage when vibrational or contraction stresses are

imposed on the metal a fissure forms. Figure shows how a hot crack initiates in a

heavy fillet weld when it is subjected to high localized contraction or shrinkage

stresses indicated by arrows.

Stage 1 Stage 2

While hot cracking propensity increases with increasing joint restraint, it is really

the presence of certain undesirable low – freezing compounds formed by stray elements

which promotes the phenomenon

Causes: The hot cracking tendency caused by phosphorous, sulphur and silicon increases

with carbon and alloy content of the steel and hence high tensile steels must have

lower percentage of these elements than in the case of mild steel. This applies as

much to the weld metal as the base metal




2.14 STANDARD TIME FOR FILLET WELDING

Size of

weld

In

mm

Horizontal fillet weld Down hand fillet weld

Time in min/mElectrode

Dia in mm

Consumption in

Electrodes/m

length

Time in

min/m

Electrode

Dia in mm

Consumption

in

Electrodes/m length

3 11.28 / 8.53 3.15 / 4.00 4.0 / 2.7 9.02 3.15 3.2

416.92 / 12.64 /

11.94

3.15 / 4.0 /

5.06.0 / 4.0 / 3.2

14.38 /

10.743.15 / 4.0 5.1 / 3.4

5 26.23 / 19.59 3.15 / 4.0 9.3 / 6.222.84 /

17.063.15 / 4.0 8.1 / 5.4

634.69 / 25.91 /

24.6

3.15 / 4.0 /

5.012.3 / 8.2 / 6.6 21.04 4.0 / 5.0 3.0 / 3.1

8 38.00 4.0 / 5.0 4.0 / 6.8 26.31 5.0 / 6.30 3.0 / 4.0

10 57.77 / 44.394.0 / 5.0 /

6.304.0 / 12.1 / 8.4 39.54 5.0 / 6.30 3.0 / 7.5

12 81.65 / 61.024.0 / 5.0 /

6.304.0 / 18.5 / 12.8 55.04 5.0 / 6.30 3.0 / 11.6

14 109.62 / 80.684.0 / 5.0 /

6.304.0 / 26.0 / 18.0 73.94 5.0 / 6.30 3.0 / 16.6

16 152.89 / 104.874.0 / 5.0 /

6.304.0 / 37.6 / 24.4 95.86 5.0 / 6.30 3.0 / 22.4

Note: Standard electrode length: 450mm

Stub length: 50mm

The above times includes the following:

I. Set up elements : II Operational Elements:

1. Electrode burning time

A. Operator set up : 2. Electrode changing time.

1. Collecting electrodes, weld shield & gloves 3. slag removal time.

2. Wear and remove gloves

3. Rest, Relaxation & contingency allowance.

B. Machine set up

1. Drawing the welding cables to the work spot 2. Welding current adjustment.




2.15 NUMBER OF STANDARD ELECTRODES PER METER LENGTH OF JOINTS:

Down Hand 50 V Butt Joint Down Hand 60 V Butt Joint

Quantity of Electrodes Effective

wt. of joint

weld metal

per meter

Quantity of Electrodes Effective wt.

joint we

metal p

meter

Plate

thk

Root

gap

Root run Filling up runs Root gap Root runFilling up runs

Either Or Either Or

mm mm Pcs/m Pcs/m Pcs/m g/m mm Pcs/m Pcs/m Pcs/m g/m

6 --- ---

/ / 2.5

/---

/ / 3.25 / /--- --- --- ---

/ / 2.5 / /

--- / / 3.25 / /--- ---

8 1 --- 14.4 6.4 166 1 --- 16.2 7.2 188

10 1 --- --- 9.2 238 1 --- --- 10.0 282

12 1 --- --- 12.6 330 1 / / 3.25 //

8

/ / 4 / /

4.6

/ / 5 / /

---

392

14 1.5 / / 3.25

/

8

/ / 4 / /

7

/ / 5 / /

---

484 1.5 8 9 --- 564

16 1.5 8 10 6.4 602 1.5 8 12.6 8 708

18 1.5 8 13.4 8.6 734 1.5 8 16.8 10.8 870

20 2 8 19 12.2 952 2 8 23 14.6 1110

22 2 8 23.4 15 1130 2 8 28.6 18.2 1330

25 2 8 32 20.2 1460 2 8 38 24.4 1710

28 2 8 38.6 24.6 1720 2 8 46.4 29.6 2040

32 2 / / 4 / /

8

/ / 5 / /

30.2

/ / 6 / /

21 2180 2

/ / 4 / /

8

/ / 5 / /

37.2

/ / 6 / /

25.8 2600

36 2 8 38.8 27 2700 2 8 47.2 32.8 3200

40 2 8 48 33.4 3260 2 8 58.2 40.4 3900

Pcs/m Pcs/m

Data for sealing run : Welding Position / / 3.25 / / / / 4 / /

Down head 4.5-6 3-4

Varies with extent of

Shipping of roots Over head 4.5-7.5 3-5




2.16 NUMBER OF STANDARD ELECTRODES PER METER LENGTH OF JOINTS :


wt. of

joint weld

metal per

meter


wt. o

joint wel

metal pe

meterPlate

thk

Root

gap

Root

run

Filling up runs Root gap Root run Filling up rums

Either Or Either Or

mm mm Pcs/m Pcs/m Pcs/m g/m mm Pcs/m Pcs/m Pcs/m g/m

6 1 ---

/ / 2.5 / / / / 3.25 / /

165 1

/ / 3.25

// / / 4 / / / / 5 / /

196--- 6.3 4 2.3 ---

8 1.5 / / 3.25

/ /

/ / 4 / / / / 5 / / 301 1.5 4 6.3 4 354

4 5 3.2

10 2 4 9.5 6.1 476 2 4 11.5 7.3 555

12 2 4 14.3 8.1 660 2 4 17 10.8 770

14 2 4 19.3 12.3 860 2 4 23.2 14.8 1020

16 2 / / 4 / / / / 5 / / / / 6 / / 1090 2 / / 4 / / / / 5 / / / / 6 / / 1300

4 15.1 10.5 4 18.6 12.9

18 2 4 19.4 13.5 1350 2 4 23.6 16.4 1610

20 2 4 24 16.7 1630 2 4 29.1 20.2 1950

Pcs/m Pcs/m

Data for sealing run : Welding Position

//3.25// //4//

Down head 4.5-6 3-4

aries with

extent of

shipping of roots Over head 4.5-7.5 3-5




COMPARATIVE CHART FOR WELDING ELECTRODES

APAR ADVANI INDIAN D & H PHILIPS GENERAL SUN-ARC

IS AWS POWER ARC OERLIKON OXYGEN SECHERON ELECTRODES

Mild Steel Type

E 100411 E 6010 XL Citojet Ferrocel/Pipecraft Cellutherme PH-31 Gricon white Pipe rod

E 100411 E 6011 ACP Gricon voilet

E 206411 E 6012 FP Ferrospeed Popular

E 206411 E 6012 Ferropace Citobest Ferrospeed Plus PH-68 Greecon Grey

E 307411 E 6013 SW (Supremeweld) Overcode Vortic/Vordian Norma PH-45 Greecon Black/ X-19

E 317412 E 6013 Steelweld -S Overcode-S Vorti-1/Vordian Media PH-28 Greecon Pink X-30

E 317412 E 6013 Steelweld -SS Overcode-SS Vordian Exobel Greecon Blue X-21

E 442411 E 6020 DH Citorex Pressureweld Unitherme

Mild Steel IRON POWDER Type

E 916411 J E 7014 ZIP-14 Comet Green Vortex-2 PH - 18 Gricon Orange

E 943412 K E 7024 ZIP-24 Comet Blue Ferrograve - 35 PH - C235 Gricon Yellow Ferrod -2

E (42412 P E 6027 ZIP-27 Cemet Red Gricon Rose

E 614512 H E 7016 LOH - 16 Universe Ferroweld - 1 Indotherme PH - 36S Greecon GreenLF - 40

E 614512 H E 7016 LOH - 16 (Special) Universe - W Indotherme C PH - 56

E 614512 H E 7016 Dynaweld Supercord Ferron - 5 P - 4 PH - 56

E 614512 HJ E 7018 WIZ - 18 Supercito Ferroweld Superatherme PH 36 H Greecon GreenFerrod - 3

E 614312 HJ E 7018 WIZ - 18(Special) Tenactio Superatherme (Spl) PH - 35

E 611XXX HJ E 8018 Dynaweld - D Tenactio - 60

E 611XXX HJ E 9018 Dynaweld - 60 Tenactio - 70 Tensal Grid - cut 1E 611XXX HJ E 10018 Dynaweld - 70 Tenactio - 75

E 10022A E 7010 A1 XL-MO Molyjet Celtian-Moly Cullutherme-MO

E 31422a E 7013 A1 SW-MO Overcord-MO Media-MO X-30(mo)

E 604XXXHJ E 7018 A1 WIZ-MO Molycord Molytherme Ferrod no.:3

E 604XXXHJ E 8018 B2 Cromoweld-1 Cromocord Cromotherme-1 Ferrod no.:4

E 604XXXHJ E 9018 B3 Cromoweld-2 Cromocord-C Cromotherme-2 Ferrod no.:7

E 604XXXHJ E 502-16 Cromoweld-3 Cromocord-D Cromotherme-5

Coding

HIGH TENSILE LOW ALLOY TYPE

LOW HYDROGEN TYPE

LOW - HYDROGEN IRON POWER TYPE

2.17




H&T-250 Citorail - I Duriod-I BOR-AR PH-250 Gridur-250 HF-250

H&T-350 Citorail - II Duriod-II A BOR-B Gridur-300 HF-350

H&T-450 Citorail - II (L H) PH-450 Gridur-500 HF-450

H&T-550 BOR-C HF-550

H&T-650 Citorail - III SHC -SIX PH-600 Gridur-600 HF-650

Hardrail-III (LH) Citorail - III (L H) Hardex-650/Duroid 3B PH-600B Gridur-600G Hardrod-55

Powermangan Citomangan Duroid-10 SMA PH-MN Gridur-M mangrod-1

Nicomangan SupremanganesePowerchrom Citocrom-13 CROMA RS 410 Grialloy-M

MBO1 - 311 E 308 - 16 Stainlessweld - 1 Superinox - 1A Rutox - A PH - RS 304C Grinox - 4 Stainrod No

MBO1 - 311 E 308L - 16 Stainlessweld - 1L Superinox - 1C Cromoweld - 308L Rutox - B PH - RS 304 Grinox - 4L Stainrod No

MBO1 Nb - 311 E 308 - 16 Stainlessweld - 1A Superinox - 1B Cromoid - 1 PH - RSS - C Grinox - 47 Stainrod No

MB01MO - 311 E 316 - 16 Stainlessweld - 2 Superinox - 2A Cromoid - 3 Rutox MO PH - RSS 316C Grinox - 16 H.T.1

MBO2MOL - 31E 316L - 16 Stainlessweld - 2L Superinox - 2C Cromoweld R Rutox D PH - RS 316B Grinox - 16L H.T.1(Elc)

MB02MONb - 3E 318 - 16 Stainlessweld - 2A Superinox - 2B Cromoid - 4 Rutox - MO(Stab) PH - RSMC Grinox - 18 Stainrod N

MB04 - 311 E 309 - 16 Stainlessweld - 3 Inbox - d2 Cronitherm 25/12 PH - RS 309 Stainrod No

MB05 - 311 E 310 - 16 Stainlessweld - 4 Inbox - CW Cromoweld - B 315 D&H - 310 - 16 PH - RS 310 Grinox - 10 Heatrod N

E 312 - 16 PE - 106 E - 106 D&H - 312 - 16 RS - 315 Excel Rod -

Eni 404 ENiCL Freemachineweld Supernicorn Ferroloid - 3 NFM PH - 801 Gricast - N Castrod No

Enicu 2/214 ENiCU - B Monelweld Superfonte Ferroloid - 1 D&H Monel PH - GM Gricast - CN Castrod No

EFEC2 Est Castweld Citocast Ferroloid - 2 Gricast - LH

E CUSnC Bronzweld Bronzweld Bronzoid Gricast - 2

Cutwell Cito cut Cutting Elect Gricon cut Cuttrode

PE - 900 E - 900 Gricon Gouge

PE - 901 E - 901

HARD FACING TYPE

STAINLESS STEEL TYPE

CAST IRON TYPES

CUTTING AND GOUGING ELECTRODES




CHAPTER-3

QUALITY CONTROL & TESTS OF GATES, PENSTOCK & ALLIED

MECHANICAL WORKS

3.0 Proper Quality Control and Quality Assurance in the manufacture and erection of

Hydraulic gates and allied equipment is very essential for attain smooth and

designed function of the System. Q C checks have to be made concurrently and

necessarily from every stage of manufacturer, assembly, installation and finaltesting.

The tests have to be performed to confirm the requirements as per the standards

and specifications. The quality assurance checks for hydraulic gates and hoists shall be

performed at all stages starting from the procurement of materials components to the final

testing of gates at site. The important stages are:

Q C tests on Raw materials brought-out items

Q C Checks during manufacturing and assembly

Q C Checks during installation

Load Testing

The following tests are to be conducted in the process and if any deficiency isnoticed, they shall b rectified before processing.

3.1 Manufacturing stage

Inspection and testing of raw material shall be conducted as per BIS specifications

for their physical and chemical properties (Rolled plates and sections, Castings,

Forgings, S S Plates, Non-ferrous castings, rubber, seals bearing etc.)

Visual and dimensional inspection.

3.1.1 Non-Destructive testing shall be conducted as per Indian standard codes

Liquid penetrate testing (IS-3658)

Magnetic particle testing as per IS: 3707)Ultrasonic testing (IS:3664)

Radiographic testing – X ray and

Gamma (IS:2595 & IS: 1182)

3.1.2 Destructive testing

Mechanical (physical properties – tensile, compression, elongation, Hardness, impact

torsion etc.)

Chemical (chemical properties – wet analysis, spectra analysis)

Assemblies and sub-assemblies checked for dimensional accuracy as per drawings

and specified tolerances of IS Codes (7718, 10096 etc)

Inspection and testing of weldments (as per BIS: 822: 3658-1980: 8780-1978: 3664-1981: 2595-1978 and ASME- (1 & 8) and latest additions for;

Soundness and strength

Weld procedures for various joints

Joint preparations

Type of electrodes

Edge preparation & root gap

Pre heating of electrodes




Weld travel speed for automatic welds and manual welding

Ensure to follow weld procedures

Selection of electrodes for each component as per recommendations of

manufacturers on its load bearing capacity ad strength of welds.

Machining items: Allowances and tolerances as per drawings and specifications for

each of the operations involved, such as; turning, planning, grinding, milling, gear

nobbing, drum scouring, drilling, boring and slotting etc.

Dimensional accuracy and critical dimensions of E.M. Parts checked at least in

300mm intervals on assembly and installation.

Dimensional accuracy and critical parameters of components / assembly of gates

and gate assembly

- Roller assembly

- Roller cage assembly

- Trunnion and pins assembly

- Yoke girders assembly

- Support/chair

- End gear box units assembly, central drive units assembly

- Control panels

-Wire rope and lifting socket assembly

- Gate lift measuring dial / indicator gauge

Rubber seals: Shore’s hardness and water absorption tests

Testing of Hoists in shop as specified.

3.2 Test during Installation/Erection Stage

Defects / mistakes after erection cannot be normally rectified, particularly in case of

the embedded parts.

Thorough second check up of all the components is done for accuracy on shifting to

erection site.

Any defect unnoticed during fabrication should be rectified before installation.

The critical dimensions of all E.M. parts must be maintained as per the given

standards and recommendation fo Indian Codes (tolerance & limits) for different

applications. The important critical dimensions that are to be ensured within the

recommended limits are;

- Roller track centre to centre

- Seal track centre to centre

- Side guide centre to centre

- Vertically of roller track, seal track, side guide track

- Co-planarity of roller track and seal track

- Horizontality of sill beam

-Levels of sill beam and hoist bridge

- Roller assembly and its alignment

- Side roller / block gap with track surface.

Equal tensions of ropes

Vibrations, if any, and remedial measures

Welds for strength and soundness




- Dirty testing of rubber sealing and pre compression

Alignment of line shafts

- Drain holes to horizontal beams, trunnion brackets, hoist bridges

- Alignment of gars & shafts

Sand blasting and painting

Surface cleaning for abrasive blasting as per Swedish Standards S A 2.5-3 white

/rough (IS: 5905-1989)

Paint specifications (binder solids, pigments, additives, solvents, driers etc.)

Thickness of paint in microns.

3.3 Additional checks for Radial Gates

Trunnion centre: coplanar and parallel to sill.

Chair level / rest plate: coplanar and parallel to sill

Inclination of yoke and anchor girders and its co plane accuracy

Side seal face to face

Level of horizontal girder

Radius of skin plate and wall plate

Pre-tension of anchorages

Site weld design and sequence Site weld testing for strength and quality

3.4 General Tools Required for Q.C. Agencies

Measuring tapes, scales and holders (blocks to carry over dimensions) Plumbobs

Micrometer Calipers (inside and outside)

Vernier calipers – linear measurements, depth gauge, height gauge, gear teeth

Dial indicators to measure deviations

Screw Micrometers

Snap gauge (pass meters)

Internal dial gauges (bore diameter)

GO & NO- GO gauges.

Bevel protractors with vernier

Taper plug (taper holes) and ring gauges (for taper shafts)

Sine bar (taper angle)

Thread gauges (dia, screw thread)

Straight edge

Surface plates angle plates, v-blocks

Machinist level

Weld measure gauges

Optical measuring gauges

Optical measuring tools Tachometer

Multi-meter (voltage, current, resistance)

Tong-tester

Theodalite / leveling instruments

Spirit levels (vertical & horizontal measurements)

Hole augers

Screw thread micrometer calipers




Screw pitch gauges

Tangential gear tooth caliper (tooth profile)

Pitch measuring tool (gears)

Bevel gar tester

Surface finish testers

Strain gauges

Testing labs – Metallurgical & chemical labs

X-ray machines for soundness of welds and porosity

Hydraulic jacks

Wire rope & socket load testing unit

Hardness testing machines (metals)

Hardness testing machines (rubber)

Pressure testing unit for water conductors

The details of general Quality Control tests performed on Gates and allied

components are tabulated below. However, the user is requested to follow the relevant

tests as recommended by the BIS and manufacturers and adopt relevant and latest

standards.

3.5 GENERAL QUALITY CONTROL TESTS FOR GATES AND ALLIED COMPONENTS

(Relevant codes and manufacturer’s recommendations are to be followed)

TESTS REQUIRED BEFORE STARTING OF WORK:

3.5.1 Raw Materials and bought out items:

3.5.1.1 Inspection and random testing of all raw materials such as:

- Steel plates;

- Rolled steel sections;

- C.I. /Cast steel casting / forgings;

- S.S. plates, non ferrous casting and other materials;

- Rubber seals;

-Bush and anti friction bearings etc;

- Gears and gear boxes – Electric motors;

- E.M. brakes etc.

a)

Visual and dimensional inspection

b)

Non-destructive testing (random)

- Liquid penetrant testing (IS-3658)

- Magnetic particle testing (IS-3707)

- Ultrasonic testing (IS-3664)

- Radiographic testing

- Ray Gama (IS-2595 and IS:1182)

c)

Destructive testing

- Physical properties, tensile, compression, elongation, hardness, impact, torsion

etc.

- Chemical Properties – wet analysis, spectra analysis.

d)

Rubber seals

- Shore’s hardness and water absorption tests




e)

Steel wire ropes (IS:2365-1963 and 2226)

f)

Welding electrodes

IS: 815-1974/E-7018 OR equivalent

IS: 1442 etc.

g)

Paints (as per specifications)

h)

Other materials as per Standard specifications.

3.6 TESTS REQUIRED DURING & AFTER INSTALLATION / ERECTION(As per IS Codes and/or manufacturer’s specifications)

A) E.M. Parts, Gates and Hoists:

1. a) Straightness and co-planner accuracy be checked for tracks and track plates.

b) Fabrication tolerances checked and maintained as per IS:7215-1974 etc.

2. Inspection and testing of weldments (as per IS: 822; 823-1964: 816: 3658-1980;

8780-1978; 3614-1981; 2595-1978 and ASME – section 1.8) and latest additions

for: -

- Size of welds - Edge preparation

-

Weld procedures for various joints - Joint preparations- Type of electrodes - Root gap

- Selection of electrodes for each component as per the standards and

recommendations of manufacturers for its load bearing capacity and strength of

welds.

- Pre-heating of electrodes weld travel speed for automatic welds and manual.

- Ensure follow of weld designs and procedures

3. Testing for Soundness and strength of welds (DPT, X-ray and gamma ray)

4. Tests for Machined items: Test for allowances and tolerances as per drawings

and BIS specifications for all items and components for which machining

operations are involved, (such as; turning, planning, grinding, milling, gear

hobbing, drum scouring, drilling, boring and slotting etc)5. Dimensional accuracy and critical dimensions of E.M. parts at least in 300mm

intervals on assembly.

6. Assemblies and sub-assemblies as per drawings and specified tolerances (IS

Codes 7718, 10096, etc)

a) Dimensional accuracy and critical parameters of components / assembly of

gates as per IS codes.

Gate assembly Seal assembly

Roller cage assembly Yoke girders assembly

End gear box units assembly Control panelsRoller assembly Guide roller assembly

Trunnions and pins assembly Support / chair

Central drive units assembly Wire rope and lifting socket

Load testing of rope & socket assembly Gate lift measuring dial/indicator gauge

7. Shop painting – surface preparation – painting process

8. Tests after Head treatment of specified components




B)

Transportation

Check for;

1. Width and length of each element should be as per norms and ceiling dimensions

of State Transport authority

2. Proper field joints, packing and safety measures

3. Special protection for machined surfaces and electrical control panels,

instruments and equipment

3.7 TESTS REQUIRED DURING THE STAGE OF MANUFACTURE

(As per IS Codes and/or manufacturer’s specifications)

1. Thorough testing & check up of components for dimensional accuracy and quality

be done on shifting to erection site. Ensure rectification of any defects unnoticed

during fabrication before installation.

2. Checking of critical dimensions of all E.M. parts at least in 300mm intervals (on

assembly and installation) during erection, before & after concreting, as per IS:

4622, 4622 and 7718 etc, as applicable with in tolerance & limits).

- Verticality of roller track, seal track, side guide track

-

Coplanar of roller track and seal track – horizontality of sill beam-levels of sillbeam and hoist bridge.

- Roller assembly and its alignment – side roller gaps

3. Test for equal tensions of ropes.

4. Testing of welds – for strength and soundness – DPT, X-ray and Gamma ray

5. Dry testing of rubber sealing and pre-compression

6. Alignment of line shafts

7. Drain holes to horizontal beams, trunnion brackets, hoist bridges.

8. Alignment of gears & shafts

9. Sand blasting and painting (IS:14177 – 1994)

-

Surface cleaning for abrasive blasting (Swedish Standards S A .25 – white /rough) and or IS:5905-1989)

- Paint specifications (binder solids, pigments, additives, solvents, driers etc.

- Thickness of paint in microns

3.7.1 Additional tests for Radial Gates

- Pre tensioning of anchor rods (as per designs)

- Trunnion centers: coplanar and parallel to sill

- Chair level / rest plate – coplanar and parallel to sill

- Inclination of yoke and anchor girders and its co plane accuracy

- Radius of skin plate and wall plate

- Site weld design and sequence

-Site weld testing for strength and quality as per IS Codes

3.7.2 Testing and Commissioning

1. Testing of gates and hoist assemblies:

a) At no load – torque, lift speed, lateral movement, vibrations

b) Full load – same as above

Leakages within permissible limits (as per relevant codes)




3.7.3 Penstock

3.7.3.1 Shop/Field Inspection

All penstock components are subject to inspection at the place of fabrication

and/or installation. The inspector must be allowed to view any or all of the operations and

have access to all report forms and radiographs.

The following documentations are required’

(1) Fabrication, welding and inspection procedures. Prior to the start of welding, copies of the following must be submitted: proposed

welding procedure specification (WPS), procedure qualification reports (PQR),

welding sequences, repair procedures, and welding rod control. Documentation

must include a weld map or table identifying each type of weld joint, the assigned

welding procedure specifications, the parts being joined, the material thickness, and

any requirements for preheat and post weld heat treatment.

Welding procedures must be qualified in accordance with Section IX of the ASME

Code.

All procedures for weld and nondestructive examination (NDE) must be submitted

prior to the start of work.

(2) Personnel qualification records

Welders and welding operators must be qualified in accordance with Section IX of

the ASME Code. Requirements for qualification include welder/welding operator

performance qualification (WPQ) tests, recorded on ASME Code forms QW 482-484,

1 or their equivalents.

Nondestructive examination (NDE personnel must be qualified under ASNT SNT-TC-

1A2 (visual examination excepted). Qualification records of NDE personnel must be

submitted to the inspector upon request.

All nondestructive testing technicians and operators must be qualified at NDT Level

II as defined in ASNT SNT-TC-1A.

All inspection work must be performed by certified welding inspectors (CWI) who

are certified in accordance with AWS QC1A provisions.

(3) Weld examination and inspection reports

These reports must include detailed records showing evidence of quality of welding.

For each section of weld inspected, a report form is required. The report must

identify the work and show the welder’s identification, the area of inspection, the

acceptance of the welds, and the inspector’s approval signature. Each report mustbe completed at the time of inspection. A complete set of forms must be supplied

upon completion of the work. For radiographic examination, in addition to the

report forms, a complete set of radiographs must be supplied.

3.7.3.2 In-Process Inspection

Prior to the start of manufacture, the owner’s inspector or designatedrepresentative must review the testing requirements of the specification and the

applicable codes and standards for tolerances.




3.7.3.3 In-Process Inspection of Fabrication

In-process inspections must include the following where applicable:

(1) Review of the purchase order and specification document requirements for

materials, fabrication, welding, examination, testing, marking, tagging, cleaning,

painting and preparation for shipment.

(2) Review of the supplier’s quality assurance programs for conformance with the

specification requirements, and discussions with the supplier’s personnel about thequality verification activities to be performed during the course of the assignment.

(3) Review of the shop drawings and other vendor documents that require submittal

prior to fabrication, including a determination that they have been approved by the

engineer, are properly stamped and released for fabrication.

(4) Review of mill test reports for all materials used in the fabrication of the penstock

sections to verify that the materials are in compliance with the specification and

applicable ASTM standards for chemical composition, mechanical properties, and

Charpy impact tests etc.

(5) Verification that the pressure and attachment material identification, heat number

and thickness correspond with the certified mill test reports provided for the job. In

addition, the owner may request the certified mill test reports for other materials.Copies of certified mill test reports must be available for inclusion in the job file.

(6) Verification that welding procedures and welders have been qualified and are

approved in accordance with the requirements of the specification, drawings, and

applicable codes and standards. This may require an in-process review of the

welding procedure specifications (WPS) and supporting procedure qualification

reports (PQR), for conformance with the specification, drawings and applicable

codes and standards, particularly if there were design or personnel changes after

the original submissions.

Welders and welding operators must have current certifications and be able to

produce acceptably sound welds with the processes, materials and welding

procedures to be used in production.(7) Verification that welding electrodes, filler materials and fluxes are identifiable,

comply with the applicable welding procedure, specification and are properly stored

in a clean and dry environment. Baked-out electrodes are required for high-

strength materials greater than 80-ksi tensile strength. Low-hydrogen electrodes

must be kept in holding ovens if not in their sealed containers.

(8) Check of all in-process welding for conformance to approved welding procedures,

drawings and applicable codes. This includes all welding parameters, preheat and

inter pass temperature requirements.

(9) Where welding repairs are required, verification that the contractor has an

approved repair and inspection procedure to ensure satisfactory defect removal and

welding of the affected area.

(10) Check of plate edges.

(11) Inspection of shell courses for concentricity and roundness and verification that the

fit-up gaps of longitudinal and circumferential joints are within the tolerances given

by the specifications.




(12) Inspection of the various parts of the penstock to ensure that all appurtenances

have been provided and that the projections and orientations are in accordance

with approved shop drawings.

(13) The inspector’s witnessing of nondestructive examination (NDE) of materials orwelds (spot check) on a random basis or as specified by the purchase order and

review of the required radiographic film to ensure that there are no indications

exceeding the limitations specified by the applicable codes and standards.

(14) Verification by the inspector that any required preheat or postweld heat treatment

has been performed in accordance with the approved procedures. The inspectormust obtain copies of time-temperature charts of each stress-relieving operation for

inclusion in the job file.

(15) For elbows, measurement of each chord to ensure that the units are fabricated as

specified and have the desired radii.

(16) For wye branches, verification of branch angle(s), projection and orientation.

(17) When bolted sleeve-type couplings and mechanical expansion joints are specified, a

review for compliance with the procurement documents of the mill test reports

provided for the couplings and gasket materials and the documentation of

nondestructive examination of welding. Couplings and gaskets must be checked for

physical damage, and dimension checks made to verify compliance with the

drawings. The longitudinal or spiral seam welds on both ends of the penstocksections must have been ground flush in accordance with the drawings or

specifications.

3.7.3.4 Coating and Lining Inspection Requirements

When corrosion protection, internal lining or external surface coating is specified in

the purchase order, a careful inspection for strict compliance with the specification,

referenced standards and Section 10 of ASCE manual is mandatory. Details of inspection

procedures for coating materials and their applications are given in Section 10 of ASCE

manual.

3.7.3.5 Final Shop Inspection

(1) Ensure that all required test reports, as-built drawings, and other documentation

generated during the fabrication of the penstock are available and processed in

accordance with the procurement documents.

(2) Prior to shipment, perform final inspection on the penstock sections, and verify that

all deficiencies have been corrected and that each section has been properly

marked.

(3) Verify the identification marks on each penstock section for conformance with

specification and drawing requirements. Confirm that the top and bottom center

lines of special section have been marked and are clearly visible on both ends of

each section.

(4) Verify that each penstock section has been properly braced to prevent damage

during transit and handling. Obtain assurance that the penstock sections will be

correctly blocked for shipment and that coated penstock sections are loaded on

padded bunks or saddles as required.




3.7.3.6Final Field Inspection

The entire penstock, including all coatings and linings, must be inspected for

damage that may have occurred during shipment and erection. All damage must be

repaired.

3.7.3.7 Damage

Damaged areas, such as scratches, gauges, grooves, or dents as determined by the

inspector, must be corrected as specified in the project specification.

3.7.3.8 Field Weld Inspection

All field welds must be inspected for conformance to the project specification and to

the requirements of Section VIII, Division 1, of the ASME code.

3.7.3.9 Field Inspection of Linings and Coatings

All coatings and linings, including those applied in the shop or field, must be

examined for damage that may have occurred during shipment and erection according to

the appropriate requirements of the specification, referenced standards, and Section 10 of

ASCE manual. All damage must be repaired.

Cathodic protection systems must be tested for electrical continuity. If an impressed

current system is in place, the power source must be given appropriate performance tests.

Documentation in the owner’s file must detail operating procedures.

3.7.3.10 Bedding and Backfill

All bedding and backfill must be inspected for conformance to the project

specification during placement and after completion

3.7.3.11 Reports

Ensure that all required test reports, as-built drawings and other documentationgenerated during fabrication and erection of the penstock are available and processed in

accordance with the procurement documents and specification.

Copies of reports for field and shop welding, NDE and repair procedures must be

included in the documentation in the project file.

3.7.4 Nondestructive Examination

3.7.4.1 General

The type of nondestructive examination (NDE) for all butt joints and certain full-

fillet lap joints in pressure retaining parts is established by the designer in conjunctionwith the weld joint reduction factors described in Section 3.5.1 of ASCE manual.

The design engineer must document the required nondestructive examinations for

these weld joints in a Fabrication and installation NDE Data Sheet. For weld joints that are

not described in Section 3.5.1 or where supplemental NDE is required, minimum

nondestructive examination requirements are listed in Table.




3.7.4.2 Minimum Nondestructive Examination Requirements (ASCE manual)

Fv< 55 ksi 55 ksi< Fv< 75

ksi

Fv< 75 ksi

CORNER JOINTS AND FILLET OF

PAD TO SHELL (SEE FIGURE

4.6.2.2(A))

100%

MT*

BLEND GRIND **

AND 100% MT

BLEND GRIND

AND 100% WET

MT

CORNER JOINTS (SEE FIGURE

4.6.1-2 (B) AND (C)

100%

MT*

BLEND GRIND

AND 100% MT

BLEND GRIND

AND 100% WETMT

FILLET WELD (SEE FIGURE 4.6.1-2

(D)

10%

SPOT MT

100% MT BLEND GRIND

AND 100% WET

MT

STUD WELD (SEE FIGURE 4.6.1-2

(E))

VISUAL 10% BEND TEST BLEND GRIND

AND 100% WET

MT

BUTT JOINTS (SEE FIGURE 4.6.1-1

(A))

SECTION

3.5.1

BLEND GRIND

AND 100% MT

BLEND GRIND

AND 100% WET

MT

FILLET-WELDED BUTT STRAPS

(SEE FIGURE 4.6.1-1 (B))

SECTION

3.5.1

BLEND GRIND

AND 100% MT

BLEND GRIND

AND 100% WET

MT

BACKED UP BUTT JOINT (SEE

FIGURE 4.6.1-1 (C))

SECTION

3.5.1

BLEND GRIND

AND 100% MT

BLEND GRIND

AND 100% WET

MT

DOUBLE FILLET LAP JOINT (SEE

FIGURE 4.6.1.-1 (D))

SECTION

3.5.1

BLEND GRIND

AND 100% MT

BLEND GRIND

AND 100% WET

MT

REPAIRS AND MATERIAL /

OVERLAY

100%

MT*

BLEND GRIND

AND 100% MT

BLEND GRIND

AND 100% WETMT

* MT applies to all final weld surfaces only.

** Blend grind is defined as the elimination of surface irregularities and fairing of

edges of the weld.

Nondestructive examination for acceptance of any material subject to hydrostatic

pressure testing must be performed prior to the hydrostatic tests. Repaired defects must

be retested by the same NDE methods used for the original tests. If the engineer

determines that the specified nondestructive testing is not possible because of conditions

encountered in the work, the engineer must choose another method of inspection. The

engineer may require additional tests and examinations.

3.7.4.3 Areas Requiring Special Consideration

(1) Where required by the project specification or the weld procedure, weld bevel

preparation in wye branches and penstocks must be magnetic-particle inspected

prior to welding. Laminations and other linear defects must be repaired in

accordance with ASTM A 20.




(2) C-girders used for reinforcement of wye branches are subjected to through-

thickness loading where the shell plates are welded to them. If the plate has

laminations in the loaded area, lamellar tearing can occur. The likelihood of this

defect occurring increases with plate thickness. Therefore, C-girder plates exceeding

1 inch in thickness should be tested ultrasonically in the area within 6 inches of the

shell -to- C-girder weld. Ultrasonic examination and evaluation must comply with

ASTM A 435, with the additional requirement that the 6-inch band adjacent to the

weld area must undergo 100% ultrasonic examination. Any defect that shows a loss

of back reflection that cannot be contained within a 1-inch-diameter circle isunacceptable. Laminations must be repaired in accordance with ASTM A 20,

Paragraph 9.4. Shell-to-bar type joints in wye branches also must be examined for

laminations in a similar manner.

Exposed edges of C-girders must be inspected by magnetic particle procedures after

postweld heat treatment.

(3) After postweld heat treatment, if required, all weld surfaces must be examined by

the magnetic particle procedure in accordance with Appendix 6 of the ASME Code,

Section VIII. If, in the opinion of the inspector, major repairs are required, stress

relieving again may be required after repairs.

3.7.5 Nondestructive Examination Methods

3.7.5.1 Radiographic Examination

All radiographic examination must be in accordance with ASTM E 94 and E 142, or

the ASME Code, Section V, Article 2. Double film must be used.

Film must be marked with the date, owner’s specification number, contract number,piece or section number, and weld number. Procedures must include an identification

system that ensures traceability between the radiographic film and the weld examined, as

well as clear location of weld defects. Radiographs and interpretation reports must be

submitted to the owner, upon request, for permanent retention.

Acceptance standards for welded joints examined by radiography must be in

accordance with Paragraph UW 51 or UW 52 of the ASME Code, Section VIII, Division 1.All defects disclosed by radiography and determined unacceptable in accordance

with the job specification must be repaired and re-radiographed.

3.7.5.2 Ultrasonic Examination

Ultrasonic examination and acceptance standards for welds other than spiral welds

must be in accordance with Paragraph UW 53 and Appendix 12 of the ASME Code, Section

VIII, Division 1.For spiral-welded pipe used in penstocks, ultrasonic test procedures and

acceptance standards must be in accordance with Section 9 of API Standard 5L.

3.7.5.3 Magnetic Particle Examination

Magnetic particle examination techniques are described in the ASME Code, SectionV, Article 7 and in ASTM E 709. Acceptance criteria must conform to the requirements of

Appendix 6 of the ASME Code, Section VIII, Division1.

3.7.5.4 Liquid Penetrant Examination

Liquid penetrant examination procedures must conform to the requirements of the

ASME Code, Section V, Article 6. Acceptance criteria must conform to the requirements of

Appendix 6 of the ASME Code, Section VIII, Division 1.




3.7.5.5 Visual Examination

Visual examination procedures must be conform to the requirements of Article 9 of

the ASME Code, Section V.

The following visual indications are unacceptable:

(1) Cracks

(2) Undercut on surface greater than 1/32 inch deep

(3) Lack of fusion on the surface

(4)

Incomplete penetration(5) Convexity of fillet-weld surface greater than 10% of the longer leg plus 3/100 inch

(6) Concavity in groove welds

(7) Concavity in fillet welds greater than 1/16 inch

3.7.5.6 Field Hydrostatic Testing

When required by engineering or the specifications, the completed penstock must

be hydrostatically tested in the field. To facilitate construction or to avoid over pressuring,

the penstock may have to be tested in sections, using bulkheads for isolation. For field tests,

some loads imposed on the structure may not be the same as those during operating

conditions. The installation must be checked, prior to testing, to determine that

anchorages and bulkheads can withstand the selected test pressure. Vacuum valves orstandpipes must be installed to prevent vacuum collapse in the event of failure of a portion

of the penstock under test.

The test pressure must be held long enough to ensure that the entire section under

test can be inspected and any leakage detected and the leakage rate measured. The leakage

rate is determined by metering the water required to maintain pressure. Depending on the

nature of the installation, the time required to perform the hydrostatic test may vary

considerably. However, the duration of testing must be sufficient to ensure the detection of

any problems. This duration may range from 1 to 24 hours. Upon reaching test pressure,

readings from pressure gages must be recorded at 10- to 30-minutes intervals depending

on the duration of the hydro test. Continuous surveillance for leakage must be performedduring the first 30 minutes and the test section must be visually inspected for leakage at 1-

hour intervals thereafter. The hydrotest must be performed during daylight hours when

practical. If any portion of the test is performed during night hours, suitable lighting for

inspection must be provided.

Hydrostatic tests are accepted on the basis of the leakage rates described in the

project specification. If a break or unacceptable leakage occurs during any of the testing

operations, the test must be terminated and the engineer notified.

Defects disclosed during the hydrostatic test must be repaired. The section must be

hydrostatically retested.

3.7.5.7 Field test Pressure

When specified, all or a specified length of pipe section must be hydrostatically

tested from a minimum pressure of 1.1 times the working pressure to a maximum pressure

of 1.5 times the working pressure or to a pressure that will produce a stress not exceeding

80% (AWWA Standard C-20010 specifies 75%) of the minimum yield strength of the steel,

whichever is less, as determined by the formula P = 2S t /D, where P = hydrostatic test




pressure, S = 0.8 times the minimum yield strength of the steel , t = wall thickness and D =

specified mean diameter of the pipe.

3.7.5.8 Hydrostatic Test Inspection Verification

For both shop and field tests, the inspector must observe the testing and check the

procedures, verifying the following:

(1) The test medium, pressures, and duration of test are as specified for the penstock

sections.(2) The calibrated pressure measuring devices provide for the recording of pertinent

data, i.e. pressure, time temperature, etc. as specified.

(3) The gauges used to monitor the pressure testing shows evidence of current

calibration traceable to the National Bureau of Standards.

(4) All seams, nozzles and manholes are inspected during the test for leaks, and findings

are recorded.

(5) The penstock section is drained, dried, and preserved after completion of testing.




CHAPTER-4

PAINTING SYSTEM FOR HYDRAULIC GATES AND HOISTS

4.0 Introduction:

Hydraulic gates, its embedded parts, gate leaf, hoists and its supporting structures

should be protected against corrosion due to climatic condition, biotechnical reaction andabrasion due to different forces acting on it. Otherwise these equipments may deteriorate

to any extent that the replacement of parts may become necessary and such replacement

may become difficult and costly. Therefore, it is necessary to do painting to protect the

equipment and to increase the life of parts. Therefore application of the paint film has two

main purposes.

The first one is to protect the steel from corrosion.

The second for decorative appearance.

Painting for hydro mechanical works shall be carried out as per IS:14177-1971 or latest.

The painting system for gates and equipment shall be attended at 2 stages.

i) Applying paint as fresh at the time of manufacture.

ii) Removal of old paint, rust and repainting during maintenance.

4.1 Surface Preparation

After the equipment has been fabricated, it is essential that before any primer and

coat of paint is applied, the surface is properly prepared. Such preparation shall include

through cleaning smoothing, drying and similar operation that may be required to ensure

that the primer and or paint is applied on suitable surfaces.

The procedure for surface preparation shall be as follows:

Weld spatters or any other surface irregularities shall be removed by any suitable

means before cleaning.

All oil grease and dirt shall be removed from the surface by the use of clean material

spirits, Xylol or white gasoline and clean wiping materials.

Following the solvent cleaning, the surfaces to be painted shall be cleaned of all rust,

mill scale and other lightly adhering objectionable substances by sand blasting.

Blast clean to a minimum of Sa 2 ½ Swedish standard SIS 05 5900 with a surface

profile not exceeding 65 microns.

The fig. B Sa 21/2 is given.




4.1.1

4.1.2

For more details of cleaning method refer IS: 1477 (part-I) – 1971.




Surface of stainless steel, nickel, bronze and machined surface adjacent to metal

work being cleaned or painted shall be protected by making tape or by other

suitable means during the cleaning and painting operations.

Primers shall be applied as soon as the surface preparation is complete and prior to

the development of surface rusting. In case there is considerable time gap, the

surface shall be cleaned prior to priming.

4.2 Shop Painting

4.2.1 Embedded parts which come into contact of concrete:

All embedded parts which come in contact with concrete shall be cleaned as detailed

above and given two coats of cement latex to prevent rusting during the shipment

while awaiting installation.

4.2.2 Embedded parts which are not in contact with concrete and gate parts:

Two coats of zinc rich primer with epoxy resin shall be applied to all embedded

parts surface which are not in contact with concrete and shall remain exposed toatmosphere or submerged in water to obtain a dry film thickness of 75 microns,

which shall be followed by two coats at an interval of 24 hours of coal tar blend

epoxy resin pair so as to get a dry film thickness of 80 microns in each coat. Total

dry film thickness of paint shall be 300 microns.

Surfaces not to be painted: The following surfaces are not to be painted unless

otherwise specified

a) Machine finished or similar surface

b) Surfaces which will be in contact with concrete.

c)

Stainless steel overlay surfacesd) Surfaces in sliding or rolling contact

e) Galvanized surfaces, brass and bronze surfaces

f) Aluminum alloy surfaces

All finished surfaces of ferrous metal including bolts, screw threads etc., that will

expose during shipment or while awaiting installation shall be cleaned and given heavy

uniform coating of gasoline soluble rust preventive compound or equivalent.

4.3 GATES:

4.3.1 Primer Coat: Over the prepared surface one coat of inorganic zinc silicate primergiving a dry film thickness of 70 + 5 microns should be applied. Alternatively, two

coats of zinc rich primer, which should contain not less than 85% zinc on dry film

should be applied to give a total dry film thickness of 75 + 5 microns.

4.3.2 Finished Paint: Two coats of solvent less coal tar epoxy paints. These shall be

applied at an interval of about 24 hours. Each coat shall give a dry film thickness of

150 +5 microns. The total dry film thickness of all the coats including primer

coating shall not be less than 350 microns.




4.4 Hoist and Supporting Structure:

4.4.1 Structural components

Primer coats of zinc phosphate primer shall be applied to give a dry film thickness of

40 + 5 microns.

Final Coats: One coat of alkyd based micaceous iron oxide paint to give a dry filmthickness of 65 +5 microns followed by two coats of synthetic enamel paint

conforming to IS: 2932 – 1974 to give a dry film thickness of 25 + 5 microns per

coat. The interval between each coat shall be 24 hours. The total dry thickness of all

coats of paint including the primary coat shall not be less than 175 microns.

4.4.2 Machinery: Except machined surfaces, all surfaces of machinery including gearing,

housing, shafting, bearing pedestals etc., shall be given the following coats of paint.

Primary Coats: One coat of zinc phosphate priming paint to give minimum film

thickness of 50 microns. Motors and other bought out items shall be painted if

necessary.

Finished Coats: The finished paint shall consist of three coats of aluminum paintconforming to IS:2339-1963 or synthetic enamel paint conforming to IS: 2932 –

1977 to give a dry film thickness of 25 + 5 microns to obtain a minimum dry film

thickness of 125 microns.

4.4.3 Machined Surfaces:

All machined surfaces of ferrous metal including screw threads which will be

exposed during shipment or installation shall be cleaned by suitable solvent and

given a heavy uniform coating of gasoline soluble removable rust preventive

compound or equivalent. Machined surfaces shall be protected with the adhesive

tapes or other suitable means during the cleaning and painting operation of othercomponents.

Note: If alternatives are chosen the guaranteed film thickness as are to be arrived at

from the data sheets of leading paint manufacturers and incorporated in the total

film thickness considering the location and atmospheric conditions of project.

4.5 Application of Paint:

Mix the contents thoroughly as directed by paint manufacturer before and

during use.

a)

Brush/roller

b) Conventional spray

c) Airless spray etc.,

Painting at shop can be done in any of the three methods so that the paint can be

made to suit the convenient direction, but once the gate and equipment are put in




position, the general method adopted is only by brush / roller. In case of spray, lot

of precautions are to be taken.

For more details: Refer IS: 1477 Part (II) – 1971.

Appendix A – Brushing of paint

Appendix B – Spraying of paint

Appendix C – Spray painting defects: Causes and remedies.

4.6 Removal of old paint/rust and carrying out fresh painting:

The carrying out of fresh painting is to be considered under the following

conditions:

Rusting is noticed all over the surface, or

Rusting is severe, or

Cracking and blistering has damaged the primer coat exposing the metal and

is noticed all over the surface, or

If the paint film has eroded badly, scrape off entire paint film to the base

metal and carry out fresh painting.

Note: In case of maintenance and renovation: Refer IS: 1477 (Part II) – 1971 for checking

and repainting.

4.7 Removal of old paint for repainting:

Caution should be exercised while removing the old paint. The surfaces shall be

derusted and descaled either mechanically or by one or more of the methods.

a) Wire brushing, Scrabing, and chipping, Sand papering or cleaning with steel

wool or abrasive paper.

b) Power tool cleaning.

c)

Flame cleaningd) Sand blasting or shot blasting and

e) Chemically rust removal.

Note: The method of application shall be decided based on conditions existing. After

cleaning, painting is to be carried out as originally proposed.

Some are painted without removal of old paint and rusting. This will amount to no

painting and deteriorate faster than the original one.

4.8 INSPECTION AND TESTING OF PAINTING

The following steps are involved in inspection of painting:

1. General Inspection before and during painting

2. Viscosity test of paints

3. Thickness test – using Elcometer

4. Inspection of general appearance of finished work.




4.8.1 General: The aim of inspection and testing is to ascertain whether the

recommended practice is being employed during every stage of application and

whether the final results fulfill the object of painting. Inspection therefore means

a close supervision while the work is in progress. Any test carried out should be

of non – destructive nature or, if of destructive nature, should be either restricted

to areas which can be restored without marring the general appearances, or be

such that it is possible to restore easily without necessitating a complete

repetition of the work.

4.8.2 Inspection of surfaces prior to painting: Inspection methods will depend onwhether an article is to be painted for the first time or is to be repainted.

4.8.2.1 New Work (Note previously painted): The following shall be decided by inspection:

a) The method of pre cleaning feasible or recommended;

b) The intermediate protective treatments to be applied, if found necessary;

c) The painting schedule and the specifications for the paint for ensuring the particular

performance required; and

d) The method of application, whether by brush, roller or spray.

4.8.2.2 Old Work (which requires repainting): The following shall be decided by inspection:

a)

Whether the entire existing paint requires removal; and

b) Whether repainting without existing paint removal would be adequate.

For ascertaining whether the old paint has deteriorated to such an extent that its

complete removal is necessary, the following test for embrittlement should be

employed;

A square coin such as a 5 paisa coin shall be pressed with the straight edge on an

angle of 45o against the paint film. This will result in a chip of paint breaking loose from the

surface if the paint has embrittled, lacks adhesion and requires removal. If the paint is not

embrittled, it will curl or shrivel up under such pressure. The square coin test should be

combined with an examination of the paint film through a magnify glass to observe theextent of cracking and a paint film which does not show the hair cracks under it may be

considered as perfectly sound.

4.8.3 Inspection during preparation of Surfaces:

Cleaning and Degreasing: At the worksite, a visual and physical inspection is

adequate. A degreased steel surface is duller in appearance than one which is even

slightly oily. Wiping the surface with a piece of white cloth will show if minute

traces of grease and dust have been left on the surface. When steel is being

degreased by wiping the surface with mineral turpentine (or any other solvent), it is

important to watch the cleaning rags are washed or changed regularly.

Derusting and Descaling:

a) Sand Blasting: The most satisfactory method of removing rust and scale is by

sand blasting. The criterion of inspection should be that the steel after

sandblasting has a grayish white metallic appearance. The surface should be

uniform in color and slightly rough. Only such a uniform appearance ensures

that the surface has been thoroughly cleaned.




b)

Hand Scraping: No definite method of inspection may be laid down for hand

scraping. It is unreasonable to expect hand scraped surfaces to be perfectly

clean, and for purposes of inspection, all loose rust or scale (and all loose paint in

case of repainting) shall have been removed.

c)

Chemical rust removal: In the case of chemical rust removal (pickling),

inspection shall make sure that washing after pickling has removed all traces of

acid. All work pieces shall be inspected particularly in inaccessible corners.

4.8.4 Inspection Before and during intermediate protective treatments:

It is important to inspect the work to make sure that no time is allowed for fresh

rust or other contamination to take place between the pre-cleaning and the intermediate

protective treatment. Inspection of the various suggested intermediate protective

treatments shall be carried out to ensure conformity with the recommended practice as

laid down in this standard and in accordance with manufacturer’s recommendations.

4.8.5 General inspection before and during Painting: When inspecting general

painting work while in progress, it should be ensured:

a) That painting follows immediately after pre cleaning or pre treatments; that any

contamination which may occur in the interim period is removed, that special

precautions are taken when painting after galvanizing;

b) That no painting is carried out when there is danger of dew;

c) That tools used are clean and not excessively worn;

d) That the paint in the drums is thoroughly mixed prior to application; that drums are

inspected to make sure that no sediment is left in them;

e) That if paint has thickened because of long storage or because of the evaporation of

the solvents, its viscosity is adjusted as recommended by the paint manufacturer;

f) That each coat is allowed to dry sufficiently but not excessively before applying the

following coat; that manufacturer’s instructions for drying time are adhered toproperly; and

g) That every individual coat is properly applied, reasonably level and smooth and free

from runs and ‘holidays’ (minute uncovered areas).

The field tests mentioned in 1 and 2 below may be carried out for facility of

inspection during the after painting.

Viscosity Test of Paints: A simple check is to verify the viscosity of the paint with

its original value at-least once during the course of its use. This may be done by

comparing the items of efflux of the paint when filled level in a viscosity cup of

standard dimensions and provided with an orifice of standard flow characteristics.

Thickness Test: The thickness of primer paints as well as the total film thickness of

all coats applied shall be verified with a suitable instrument. It is important that the

setting of the thickness meters is checked prior to the test and for this purpose

standardized test bits are supplied with every instrument. It should be noted that

instruments like the Elcometer contain a delicate magnet and that the storage and

handling of such instruments needs care to ensure that they retain their accuracy.




4.9 SPRAY PAINTING DEFECTS: CAUSES AND REMEDIES

4.9.1 Defects in finish

I Sags

S.No. Possible cause Suggested remedies

i) Dirty air cap and fluid tip (distorted

spray pattern)

Remove air cap and clean tip and air cap

carefully

ii) Gun stroked too close to the surface Stroke the gun 150 to 250mm from surfaceiii) Trigger not released at end of stroke

(when stroke does not go beyond

object)

Operator should release the trigger after

every stroke.

iv) Gun stroked at wrong angle to the

surface

Gun should be stroked at right angles to

the surface

v) Paint applied too heavily Regular flow of paint

vi) Paint thinned too much Add the correct amount of solvent by

measure

II Streaks

i) Dirty air cap and fluid tip (distorted

spray pattern

Remove air cap and clean tip and air cap

carefully.

ii) Insufficient or incorrect overlapping of

strokes

Follow the previous stroke accurately to

deposit a wet coat

iii) Gun stroked too rapidly (‘dusting’ ofthe paint)

Avoid ‘whipping’ and use deliberate slowstrokes.

iv) Gun stroked at wrong angle to the

surface

Gun should be stroked at right angles to

the surface

v) Stroking too far from surface Stroke 150 to 250 mm from surface

vi) Too much air pressure Use less air pressure as necessary.

III. Orange Peel

i) Paint not thinned out sufficiently Add the correct amount and the right type

of solvent by measure

ii) Not depositing a wet coat Check solvent. Use correct speed, overlap

and stroke.

iii) Gun stroked too rapidly (‘dusting’ ofthe paint)

Avoid ‘whipping and use deliberate slowstrokes.

iv) Insufficient air pressure Increase air pressure or reduce fluid

pressure

v) Using wrong air cap or fluid nozzle Select correct sir cap and nozzle formaterial and feed.

vi) Gun stroked too far from the surface Stroke the gun 150 to 250 mm from the

surface

vii) Overspray striking a previously

sprayed surface

Spray detail parts first. End with a wet

coat.




4.9.2 Defects in Workmanship:

I Excessive Paint Loss

S.N. Possible cause Suggested remedies

i) Not ‘trigging’ the gun at each stroke It should be a habit to release trigger after

every stroke.

ii) Stroking at wrong angle to surface Gun should be stroked at right angle to surface

iii) Stroking gun too far from the surface Stroke the gun 150 to 250mm from the surface

iv) Wrong air cap or fluid tip Ascertain and use correct set up.v) Air pressure is too high Use the least amount of air as necessary

II Excessive Spray Fog, Surface Haze or Bloom

i) Too high air pressure Use least amount of compressed air as

necessary

ii) Spraying past surface of the product Release trigger when gun passes target

iii) Wrong air cap or fluid tip Ascertain and use correct set up

iv) Gun stroked too far from the surface Stroke the gun 150 to 250 mm from the

surface

v) Material thinned out too much Add the correct amount

vi) Too humid an atmosphere Spray during dry period. If not use retardersor slow evaporating solvents as advised by the

manufacturers.

III Paint will not come from Spray Gun

i) Out of paint (Gun begins to sputter) Add paint, correctly thinned out and strained

ii) Settled, caked pigment blocking gun

tip.

Remove obstruction, strip paint thoroughly

iii) Grit, dirt, paint skins etc., blocking gun

tip, fluid valve or strainer

Clean spray gun thoroughly and strain the

paint. Always strain paint before using it.

IV Paint will not come due to defects arising from Pressure Tank

i) Lack of air pressure in pressure tank Check for leaks or lack of air entry

ii) Air intake opening, inside of pressuretank lid, clogged by dried up paint

This is a common trouble. Clean the openingperiodically.

iii) Leaking gaskets on tank over Replace with a new gasket

V Gun sputters constantly

i) Fluid nozzle not tightened to spray gun Tighten securely, using a good gasket

ii) Leaky connection on fluid tube or

needle packing (suction gun)

Tighten connections. Lubricate packing

iii) Fluid pipe not tightened to the

pressure tank lid.

Tighten. Check for defective threads.

VI Paint leaks from spray gun

i) Fluid needle pacing nut too tight Loosen nut. Lubricate packing

ii) Packing for fluid needle dry Lubricate this part daily

iii) Foreign particle blocks fluid tip Remove the tip and clean

iv) Damaged fluid tip or needle Replace both tip and needle

v) Wrong size needle Use correct combination.



Himachal Pradesh


O. K. Cards – Specimen

(Civil & HM Works)



Quality Assurance & Quality Control Page-1


QUALITY CONTROL DEPARTMENT

Card No…………………….

O.K. Card for ExcavationContract No…………………………

Tunnel Cavern/Open Excavation Start (RD) From……………………………..To…………………….…….

EL From…………………………...To………………………….

Ref. Const. Drawings No………………………………………………

Date/Time/Shift………………………………………………………………………………………………………………

Sr.

No.

Description Signature Remarks

Contractor HPPCL Const.

1. Layout

2. Rock Excavation

3. Rib Erection (Nos)

4. Spacer B/W Ribs & Struts (Nos)

5. Rock Bolting/Anchoring

6. Wiremesh Placement

7. Shotcreting (cum)

8. Packing Including Wedging/

back filling (cum)

9. Grouting, Drainage &

Forepoling

10. Geotechnical Mapping11. Drilling pattern including blast

time

12. Defuming/site clean up

13. Final O. K. for next blast

NOTE: - 1) These cards shall be signed with date by Authorized Construction

representatives of the contractor & HPPCL, not below the rank of HPPCL

Engineer. Full name shall be indicated in block letters. Cards shall be put in

the O. K. Box before the next operation is commenced.

2) One card shall be signed jointly by both construction representative & control

representative of HPPCL besides the contractor every fortnightly.






Card No…………………….

QUALITY REPORTS

ROCK EXCAVATIONStatus of Rock Vol. of Excavation Remarks

SHOT CRETEQty. of Shot

Crete

W/c Ratio Type of

cement

% Refusal No. of Panel

Casted

Nozzle man

Efficiency

Type of

Admixture

BACK FILL CONCRETEQty. of Cement W/e Ratio Type of Cement Qty. back filled

ROCK DRILLINGLength of

Drill Hole

Type of

explosive

used

No. of

detonator

used

Blasting

Time

Defuming

Time

Scaling Time Mucking

Time

GROUTING

Method ofGrouting

Type of Hole Grout Mix Qty. of cementin Bag

PercolationTest

PressureTesting






Card No…………………….

O. K. Card for Underground Structures-Concrete Lining

Contract No. R. D. from…………….……………….To………………………

Tunnel/Cavern E. L. From……………………………To………………………..

Ref. Const. Drawing No……………………………………...

Sr.

No.


Contractor HPPCL

1. Rock Excavation

2. Bottom clean up

3. Ground Mat

4. Initial O. K. including ribs

5. Concrete surface preparation with sand

blasting/chipping air & water jet cleaning,

grinding of edges etc.

6. Reinforcement

7. Grout Nipples

8. Drainage Pipes

9. Cooling Pipes

10. Embedments for instrumentation

11. Water stops

12. Gantry form with inspection windows/concrete

placement windows

13. Oiling of Forms

14. Form Vibrations

15. Final Clean up

16. Type of Concrete Mix

17. Final O. K. for Concrete Placing

NOTE: - 1) These cards shall be signed with date by Authorized Construction

representatives of the contractor & HPPCL, not below the rank of HPPCL

Engineer. Full name shall be indicated in block letters. Cards shall be put in

the O. K. Box before the next operation is commenced.

2) One card shall be signed jointly by both construction representative & control

representative of HPPCL besides the contractor every fortnightly.






Card No…………………….

Quality Report on Pour No………………………………………………………………………………………………...

Date…………………………..Time Started…………………………………..Hours……………………………............

Date…………………………..Time Completed……………………………..Hours…………………………………….

Class Volume Batched (m3) Volume Wasted (m3) Type of Cement used Remarks

OBSERVATION ON PLASTIC CONCRETEClass Tested Slump

(mm)

Air % Yield Temp. Co. Specimen Cast Remarks

Date Time Conc. Air Cubes Cylinder






Card No…………………….

O. K. Card for Placement of concrete for DAM/OPEN WORKS

Contract No.

a) Feature: -

b) Block No………………………………………Co-Ordinate……………………………………………………….....................................

c) Lift Elevation………………………………………..From………………………………….To……….………………………....................

d) Placing Method…………………………………………………………………………………………………………………….....................e) Concrete Specifications: - Class……………………………….Estimated Qty…………………….………………......................

Sr.

No


Contractor HPPCL

1. Survey : Layout Levels

2. Excavation

3. Foundation Treatment

4. Geotechnical Mapping Including

Rock Anchors

5. Civil - Initial clean-up

- Form Work

- Surface Preparation

- Anchor Bolts

- Water stop joint filler

- Reinforcement

- Embedded steel

- Opening/Blockout

- Joint Treatment- Protection lighting

- Final Clean-up

6. Instrumentation: -

Installation & Embedments

7. Mechanical: - Embedments

8. Electrical: - Embedments

9. Miscellaneous

10. Final O. K. to Place Concrete

Date………………………………Time…………………………….For Contractor…………………………………………………..................

Date……………………………….Time……………………………For HPPCL Const. Department…………………………..................

Date……………………………….Time……………………………For HPPCL (Q. C.)………………………………………………................

This O. K. card validated for 24 Hrs. only (Rep. QC Deptt…………………………………………………………………..............

NOTE: - 1) These cards shall be signed with date by Authorized Construction representatives of the

contractor & HPPCL, not below the rank of HPPCL Engineer. Full name shall be indicated in

block letters. Cards shall be put in the O. K. Box before the next operation is commenced.






Card No…………………….

Quality Report on Pour No………………………………………………………………………………………………... Date…………………………..Time Started…………………………………..Hours……………………………............ Date…………………………..Time Completed……………………………..Hours…………………………………….

Class Volume Batched (m3) Volume Wasted (m3) Type of Cement used Remarks

OBSERVATION ON PLASTIC CONCRETEClass Tested Slump

(mm)

Air % Yield Temp. Co. Specimen Cast Remarks

Date Time Conc. Air Cubes Cylinder






Card No…………………….

Placement Report Contract No.

Feature: -

(To be submitted to Executive Engineer, Superintending Engineer, Quality Control)

Date and Time of Start…………………………………………………………..BlockNo……………………………………….

Date and Time of Finish………………………………………………………..................

R. D. From………………………………………To…………………………………...............

E. L. From……………………………………….To…………………………………...............

CONCRETE DETAILS: -

Sr.

No.

SHIFT TOTAL QTY.

Concrete Grade

Total……………………………… Shift………………………………. Shift wise inspection report

1. Vibration

2. Grout Pipe

3. Forms

4. Cold joints

5. Slope of concrete surface, towards the

drain pipe and grade at all boundries

6. Wriglling round corners of gutter,

gallaries and oil seals

7. Finish of lite Hydro-blasts ( )

Green Cut ( )

Wood Flood ( )

Steel Trowel ( )

8. Signature of representative Const. Deptt………………………………………………………………… .

9. Signature of representative of Quality Control Deptt…………………………………………………






Card No…………………….

REINFORCEMENT INSPECTION CHECK LIST

Package : - Quali

Recor

No - Q10bContractor: -

Structure and Element

CONTRACTORS INSPECTION REQUEST No.

Sr. No DescriptionRemarks

YES NO NA

1 Reinforcing steel material approved

2 Bar bending and cutting satisfactory

3 Bar sizes correct

4 Bar spacing correct5 Bar lap lengths correct

6 Bar laps at correct locations

7 Bar tied as specified

8Bar assembly rigid and adequately supported

( including spacers & chair supports)

9 Cover to bottom bars correct

10 Covers of bars correct

11 Cover blocks approved including fixing

12 Levels of reinforcement correct

13 Cleaning of reinforcement completed14 Details of Lap provided

a.

b.

c.

d.

15 Details of chairs / spacers provided

Tested By Checked By Verified By

For Contractor For Engineer






Card No…………………….

Plain and Reinforced Cement Concrete work

Name of work: - Agency: -

Contract/Package No: - Location: -

Date: -

Description of activities Remarks & dated

signature of

construction

agency

Remarks & dated

signature of

construction

engineer

Remarks & dated

signature of QC

engineer

- Material suitability

1. Cement

2.

Steel

3. Coarse aggregate

4.

Fine aggregate

(sand)

5.

Water

6.

Admixture

OK for materials

- Form work & centering

1.

Tightness, stability

& smoothness

2.

Cleaning, oiling &

perfectness of form

work

3.

RL of centering

4.

Checking ofreinforcement

OK for reinforcement

Misc.

1. Cleanliness of

surface where

concrete is to be

poured.

2. Surface treatment

for construction

joints.

3.

Water stop4.

Expansion joints






Card No…………………….

- Tools & plants

1.

Batching & mixing

plant and vibrators

2.

Adequacy of

concrete production,

transportation,placement &

consolidation

OK for tools & plants

adequacy

- Final placement of

concrete

1.

Cleanliness of

surface

2.

Design mix

measurement

3.

Mixing consistency4. Slump

5.

Compaction of

concrete

6.

Finishing

7.

Casting of cubes

8. Curing

9.

Compressive

strength at 28 days

10.

Embedments if any

Final OK






Card No…………………….

Compressive strength of concretePackage: -

Contractor: -

Name of Component: -

Date ofCasting

Date ofTesting

Grade ofConcrete

Qualityin m3

Ageof

Test

Locationof

pouring

No. ofCubes

Casted

7 daysAverage

Strength

28 daysAverage

Strength

ContractorsRep. Sig

HPPCLRep.

Sig.

Rem

Load

in KN

Str. In

N/mm2

Load

in Km

Str. In

N/mm2

Avg.

Avg.

Avg.

Avg.

Avg.

Avg.


Signature Signature: Signature

Name: - Name: - Name: -

Date: - Date: - Designation: -

Date: -






Card No…………………….

ROCK BOLT TEST RESULT

Name of Project: -

Name of contractor: -

Name of Site: -

Date of test: -

1

Type of rock bolt Expansion/Resin/Anchor/ Cement Grouted

2

Location & R: D

3

Length of rock bolt 3200/4000/4500/5000/6000/8000

4 Rock bolt classification Class1/ii/iii/iv/v

5

Dia of hole 45mm/38mm/32mm/51

6

Length of hole mm

7 Bearing plates size & Thickness 150mm x150mm x10mm {300mm

x300mm x16mm}

8 Dia of hole in bearing plate mm

9

Length of threaded portion mm

10 Dia of thread mm

11

No & size of resin capsule used No. Dia mm Length mm

12 Manufacture ‘ Name Buildtech /Hind/ Sika/Appex

a) End anchorage 900 mm

b) Design requirement 900 mm

13

Dia of rock bolt 25 mm, 32mm

14

Maximum Permissible limit of displacement 40mm

Load Tons 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Displacement Reading

(mm)

Maximum Pull (Tons ) 17 Tons

Maximum Displacement

(mm)

mm

Nature of failure O.K. (NO FAILURE)/FAIL

Remarks







Card No…………………….

SIEVE ANALYSIS FOR SAND/FINE AGGREGATE (IS: 383)

PackageQuality Record

No - QR-

Contractor

Source: -Sample No: -

Sampled By: -Tested By: -

Date of sampling: - Date of testing: -

Weight of sample taken: -

Sieve size

(mm)

Weight

Retained

(gm)

Cumulative

Wt. Retained

(gm)

Cumulative %

Retained

% of

Passing

Specified limits

(MOST Cl. 1000.2)

Zone I Zone II Zone III

10 100 100 100

4.75 90 - 100 90 - 100 90 - 100

2.36 60 - 95 75 - 100 85 - 100

1.18 30 - 70 55 - 90 75 - 90

0.6 15 - 34 35 - 59 60 - 79

0.3 5 - 20 8 - 30 12 - 40

0.15 0 - 10 0 - 10 0 - 10

Pan 0-3 0-3 0-3F.M.

Silt @ 3hrs.

by Volume

Remarks:


Signature

Name:

Date:

Signature

Name:

Date:

Signature

Name:

Designation:Date:






Card No…………………….

CALIBRATION OF BATCHING PLANT Package: - Quality Rec

No – QR-Contractor: -

Frequency : Monthly

Location: Make/Model: Steller Plant Capacity of B. P. = 0.5m3/30m3 per hrs.Date of Calibration: Date of next Calibration:

AGGREGATE: LOADING SEQUENCE UNLOADING SEQUENCE CEMENT & WATER – LOADI

Actual

Load

(Kg)

Indicated

Load (Kg)

(+/-)

%

Error

Remarks Actual

Load

(Kg)

Indicated

Load (Kg)

(+/-)

%

Error

Remarks ctual

Load

(Kg)

Indicated

Load (Kg)

(+/-)

%

Error

Rem

s

ADMIXTURE: LOADING SEQUENCE UNLOADING SEQUENCE CEMENT & WATER–UNLOAD

Actual

Load

(Kg)

Indicated

Load (Kg)

(+/-)

%

Error

Remarks Actual

Load

(Kg)

Indicated

Load (Kg)

(+/-)

%

Error

Remarks

Note: As per DTS, CI 11.7.2

As per I.S. 4926-2003

Tolerances for Cement = ± 2

Aggregate & Water ± 3%

Chemical Admixture = ± 3%

For The Contractor For The Engineer






Card No…………………….

SAFETY CHECKLIST

PackageQuality Record

No - QR-

Contractor

Structure and Element

CONTRACTORS INSPECTION REQUEST NO

S. No. ITEMS YES NO

1 All workers engaged in bore muck / slush wear gum boot

2 Workers working with wire rope wearing gloves

3 All workers wearing safety helmets

4Safety cordon is provided around excavated foundation location &

Underground water tank

5All switch board are properly covered and electrical lines are carried on

bamboo poles with insulated wires

6 Welders and gas cutters are wearing welding helmets and Gloves

7 Earthing is done using insulated cables

8Emergency medical kit and other emergency facilities are provided at

site

9Lights are properly covered using insulated wires, Halogen Lamps and

Hand lamp with wire mesh covering

10 Hot cutting scrap are quenched and remove properly

11 Oil, fuel installation stock yard are properly protected with temp. firefighting equipments

12 Safety officer and supervisors are available at site

13All cranes JCB Hydra etc. Drivers / operators have the required

certificates

14Proper warning sign board / instruction board in Hindi,English and

Punjabi should be affixed by the contractor

For Contractor For Engineer



Quality Assurance & Quality Control Page- 16

1 & 2 Stage Embedments

QP NO.:

REV.0,

DATE:

SL. NO. ACTIVITY AND

OPERATION

CHARACTERISTICS /

INSTRUMENTS

CLASS OF

CHECKTYPE OF CHECK

QUANTUM

OF CHECK

REFERENCE

DOCUMENTS ACCEPTANCE NORMS REMARK

1 2 3 4 5 6 7 8 9 D* 10

1st Stage Emb. Parts ,Radial Gates (with & without flap),vertical gates,

1 Dimensinal Check Measuring Instrume Major Measurement 100%

Appd. Drawing/ data

sheet

Appd. Drawing/ data

sheet Site register

2

Identification of sub

componenets Dispatch doc/drg Major Qty check 100% Drg/Dispatch doc. Drg/Dispatch doc. Site register

1 Dimensinal Check

Measuring

Instrument Major Measurement 100% Appd. Drawing/ data shAppd. Drawing/ data Site register

2


componenets Dispatch doc/drg Major Qty check 100% Drg/Dispatch doc. Drg/Dispatch doc. Site register

3 Site welding i f any WPS/welding Major DP Test 10% Approved WPS Approved WPS Site register

4 Alignment & Flatness Measurement Major Measurement 100% Appd. Drawing Appd. Drawing Site register

5

Alignment of gate

roller assly & its freerotation Measurement Major Measurement 100% Appd. Drawing Appd. Drawing Site register

6 Concreting

Horizontal/Vertical

surface Major Levelling Inst. 100% Contractor Procedure Contractor Procedur Site register

REVIEWED BY APPROVEDSIGNATURE

LEGEND : *RECORDS IDENTIFIED WITH "TICK" (√ ) SHALL BEESSENTIALY INCLUDED BY CONTRACTOR IN QA

DOCUMENTATION.LEGEND TO BE USED: CLASS#:

A=CRITICAL,B=MAJOR, C=MINOR; 'A' SHALL BE WITNESSED

BY HPPCL FQA. 'B' SHALL BE WITNESSED BY HPPCL

ERECTION/ CONSTRUCTION ,C: SUPPLIER/ NOMINATED

AGENCY

MANUFACTURER/

SUB-SUPPLIER

FOR HPPCL USE

PROJECT :FIELD QUALITY PLAN

DOC. NO. RE

MAIN-SUPPLIER

FORMAT OF RECORD

PACKAGE :

CONTRACT NO.:

MAIN-SUPPLIER :

2nd

Stage Emb. Parts ,Radial Gates (with & without flap),vertical gates,

SUB-SYSTEM :

SUPPLIER'S NAME & ADDRESS:

SUPP-LIER'S

LOGOITEM : ERECTION OF EMBEDE PARTS FOR ALL RADIAL &

VERTICAL LIFT GATES /STOPLOGS




Authorization Powers

Classification/

CategorisationWitnessing & accepting Authority Surveillance By HPPCL

Category-A

(Critical)

FQA Engineer in association with

Executing Engineer

HEAD (FQA)

Category-B

(Major)

Executing Engineer FQA Engineer

Category-C

(Minor)HPPCL Executing Engineer

Another Executing Engineer

authorised by Head

(Executing Department)

HPPCL AUTHORIZATION FOR DIFFERENT CATEGORY / CLASS OF CONSRUCTION / ERECTION CHECKS




DT Gates

QP NO.:

REV.0, DATE:

SL. NO. ACTIVITY AND

OPERATIONCHARACTERISTICS /

INSTRUMENTSCLASS

OF

CHECK

TYPE OFCHECK

QUANTUMOF CHECK

REFERENCEDOCUMENTS

ACCEPTANCENORMS

REMARKS

1 2 3 4 5 6 7 8 9 D* 10

1 DT GATES

1.01 Dimensional Measuring inst B

Measurement 100%

Appd

Drag/datasheet

Appd

Drag/datasheet Site register

1.02


- comp Despatch doc/measuring B 100% Drg/Desp . Doc Drg/Desp . Doc Site register

1.03

Prep of concerete

foor Horizontal surface B Leveing Inst 100%

Contractor

procedure

Contractor

procedure Site register

1.04

Const of temp

stage Dimn ; Stabiity B

Visual/measur

e 100%

Contractor

procedure

Contractor


1.05

Assy of gate

element Straightness & horizontal A

Visual/measur

e 100%

Appd

Drg/Contractor

Precedure

Appd Drg/OMML

Precedure Site register

1.06 Site welding if any WPS/Welding test B DP Test 100% Approved WPS Approved WPS Site register

1.07

Allignment &

flatness of seal

base pate Measurment B Measurement 100% Appd Drg/ Annex 1 Appd Drg/ Annex 1 Site register

1.08

Allignment of gate

wheels assly &its

free rotat ion Measurment & wire A Measurement 100%

Appd Drg /

Annexure 1

Appd Drg /

Annexure 1 Site register

1.09

Lowering of gate in

groove

Sea Precompression,

imit of precompression of

rubber seal A

Fuly cosed to

fully raised

posn 100%

Appd Drg /

Annexure 1 Appd Drg / Annex 1 Site register

1.1 Tria run of gate Visual/Measurement A

Lowering&Rai

sing 100% Appd Drg / Annex 1 Appd Drg / Annex 1 Site register

1.11

Hydraulic HoIst

Installation A 100% As per annexure 11

REVIEWED BY APPROVED BY


FOR HPPCL USE

DOC. NO. REV. ...

PACKAGE :

MAIN-SUPPLIER

FORMAT OF RECORD

SIGNATURE

LEGEND : *RECORDS IDENTIFIED WITH "TICK" (√ )SHALL BE ESSENTIALY INCLUDED BY CONTRACTOR

IN QA DOCUMENTATION. LEGEND TO BE USED:

CLASS#: A=CRITICAL,B=MAJOR, C=MINOR; 'A' SHALL

BE WITNESSED BY HPPCL FQA. 'B' SHALL BE

WITNESSED BY HPPCL ERECTION/ CONSTRUCTION

MANUFACTURER/

SUB-SUPPLIER

CONTRACT NO.:

MAIN-SUPPLIER :

SUPP-LIER'S

LOGO


ITEM :

SUB-SYSTEM :




DT Gates 2nd Stage

QP NO.:

REV.01, DATE:

SL.NO.

ACTIVITY ANDOPERATION

CHARACTERISTICS / INSTRUMENTS

CLASS OF

TYPE OFCHECK

QUANTUMOF CHECK

REFERENCEDOCUMENTS

ACCEPTANCENORMS

REMA

1 2 3 4 5 6 7 8 9 10

Second Stage

Embedded parts as per

drawings/ sketch for DT

roller gate

1

Overall dimension/

location B Measurement 100% Drg log book

2


component B Visual 100% Drg log book

3

Centering,levelling &

alingment B Measurement 100% Drg log book

4 Assembly filment B Measurement 100% Drg log book

5 Field welding

a) fillet welding/ butt

welding A

WPS/PQR

Qualified welder 100%

ASME Sec IX

ASTM T2,168 No

inspection

record

b) DP test on finalbutt weld B DP test 100% linear defect

inspectionrecord

6

Template check for

embedded parts A Template 100% As per drg

inspection

record

REVIEWED BY APPROV

FIELD QUALITY PLAN

FOR HPPCL USE

PACKAGE :

SIGNATURE



CLASS#: A=CRITICAL,B=MAJOR, C=MINOR; 'A'

SHALL BE WITNESSED BY HPPCL FQA. 'B' SHALL BE


DEPTT. AND 'C' SHALL BE WITNESSED BY MAIN

SUPPLIER (A & B CHECK SHALL BE HPPCL )

ITEM : Erection of Gates

SUB-SYSTEM :

MAIN-SUPPLIER

FORMAT OF RECORD

MANUFACTURER/

SUB-SUPPLIER


SUPP-

LIER'S

LOGO CONTRACT NO.:

MAIN-SUPPLIER :

DOC. NO.

PROJECT :




Erection of Gates

QP NO.:

REV.0, DATE:

SL.

NO.

ACTIVITY AND

OPERATION

CHARACTERISTICS

/ INSTRUMENTS

CLASS OF

CHECK

TYPE OF

CHECK

QUANTU

M OF

CHECK

REFERENCE

DOCUMENTS

ACCEPTANCE

NORMSREMARKS

1 Dimensional Measuring instrument Major Measurment 100%

Appd. Drg./data

sheet

Appd. Drg./data

sheet Site register

2

Identification of

subcomp

Dispatch

doc/measure/drg Major 100% Drg./Dispatch doc. Drg./Dispatch doc. Site register

3

Prep of concrete

floor

Horizontal & vertical

surface Major levelling inst. 100%

Contractor

procedure

Contractor


4 Const of temp stage Dimn. Stability Major Visual/ measure 100%

Contractor

procedure

Contractor


5 Site welding if any WPS/welding Major DP test 100% Approved WPS Approved WPS Site register

6 Gate asssembly Measurment Major

Fully closed to

fully raised

position 100%

Approved

Drg./Contractor

Procedure

Approved

Drg./Contractor

Procedure Site register

7

Lowering of gate in

groove

precompression, lt.of

precompression Major

fully raised

position 100%

Drg./Contractor

Procedure

Drg./Contractor


8 Trial run of gate Visual/ measurment Major

Lowering &

raising 100%

Approved

Drg./Contractor

Procedure

Approved

Drg./Contractor


B

Final testing of

gates

9 Dry condition

operation of gate &

hoist Major

Lowering &

raising 100%

Drg./Contractor

Procedure

Drg./ContractorL


10 Seal test Visual/ measurment Major Filler gauge test 100%

Approved

Drg./Contractor

Procedure

Approved

Drg./Contractor



FIELD QUALITY PLAN

FOR HPPCL USE

PACKAGE :

SIGNATURE

LEGEND : *RECORDS IDENTIFIED WITH "TICK" (√ )SHALL BE ESSENTIALY INCLUDED BY CONTRACTOR IN

QA DOCUMENTATION. LEGEND TO BE USED: CLASS#:

A=CRITICAL,B=MAJOR, C=MINOR; 'A' SHALL BE

WITNESSED BY HPPCL FQA. 'B' SHALL BE WITNESSED

BY HPPCL ERECTION/ CONSTRUCTION DEPTT. AND 'C'

SHALL BE WITNESSED BY MAIN SUPPLIER (A & B

CHECK SHALL BE HPPCL)

ITEM : Erection of Gates

SUB-SYSTEM :

MAIN-SUPPLIER

FORMAT OF

RECORD

MANUFACTURER/

SUB-SUPPLIER


SUPP-

LIER'S

LOGO CONTRACT NO.:

MAIN-SUPPLIER :

DOC. NO.

PROJECT :




Gantry Crane Hoist

QP NO.:

REV.No,

DATE:

S r.No A CTIV ITY AND OPE RA TIO NCHARACTERISTICS /

INSTRUMENTS

CLASS OF

CHECK

TYPE OF

CHECK

QUANTU

M OF

CHECK

REFERENCE

DOCUMENTS

ACCEPTANCE

NORMSREMARKS

1 2 3 4 5 6 7 8 9 10

A Material receipt

(1) Check for the

availability of

document A Visual 100%

Packing

list/loading

advise

slip/MDCC/CHP/

BBU/DRG.

Appd

drgs.relevant IS

codes log book

(2) Verify the

components/items

received for following

a) loose/ open A Visual 100%

Packing

lis/loading advise

slip/MDCC/CHP/

BBU/DRG.

Appd

drgs.relevant IS

codes log book

b) item num./drg. No.

(3) Check the

components/ item on

receipt for the

following

a) loose/ open

b) physical damage A Visual 100%

Packing

lis/loading advise

slip/MDCC/CHP/

BBU/DRG.

Appd

drgs.relevant IS

codes log book

c) shortage/excess of

quantity

(4) ensure

nonconfirmity &

rejection components

& stored separately B Visual 100%

Packing

lis/loading advise

slip/MDCC/CHP/

BBU/DRG.

Appd

drgs.relevant IS

codes log book

(5) Storage of all items

of scope of supply of

gantry crane A Visual 100%

Packing

lis/loading advise

slip/MDCC/CHP/

BBU/DRG.

Appd

drgs.relevant IS

codes

As per storage

manual

(6) Ensure control of

list & issue of all

components B Visual 100%

Packing

lis/loading advise

slip/MDCC/CHP/

BBU/DRG.

Appd

drgs.relevant IS

codes log book

B

Pre errection/errection

chartMeasurement

equipment B Visual 100% Appd drg./ data sh

Appd drg./ data

sheet site register

a) Gantry girder bracket top level

on the column alignment Measurement A water level 100% Protocol

(b) Top flange level of gantry

girder alingment Measurement A water level 100% Protocol

gravity Measurement B water level 1000% Protocol

alingment/straightens,level,elevati Measurement B water level 100% Protocol

(e) Joining of girder, movement of

wheels,placement & pertaining of

eletrical pannel Measurement B Logbook

(f) Cable connection,continuity

check & IR Measurement B Logbook

(g) Gear box alignment with motor

& check for oil level Measurement A Protocol

(h) LT machinary, electrical

equipment other structural

componenets,limit swtich & mech

stopper atc. Fill up & allignment B visual 100% Approved drg. Logbook

Comissioning checks 100% Approved d rg .

a) All cable connections IR Measurement A 100% Approved drg. Logbook

b)Earthing A 100% Logbook

c) Operation of brakes A 100% Logbook

d) Operation of limit switch B 100% Logbook

e) Motor IR value & earthing B 100% Logbook

& crane speed A 100% Logbook

& crane speed A 100% Logbook

h) At 25% over load check motor

current & crane speed A 100% Logbook

C

Dimensional check for assembled

crane Dimensional check B

Measurment

check 100% As per drawing As per drawing

Random check

by HPPCL site register

D Welding if any 1) W PS/P QR A W PS RT /DP/U T 1 00 % A s pe r drawing As per drawing NDT report

2) NDT A

E Assembly B

Measurment

check 100% As per drawing As per drawing As per drawing site register

F Rope Drum Visual & measurment ALowerinn &Raising 100% Approved d rg . Approved drg. site register

G Trial run of gantry crane Visual & measurment A 100% Approved drg. Approved drg. site register

H Load test

1.25 times of design

load A Measurment 100% As per drawing As per drawing Report


FORMAT OF RECORD

MANUFACTURER/

SUB-SUPPLIER


SUPP-LIER'S

LOGO

CONTRACT NO.:

SIGNATURE



CLASS: A=CRITICAL,B=MAJOR, C=MINOR; 'A' SHALL



DEPTT. AND 'C' SHALL BE WITNESSED BY MAIN

SUPPLIER (A & B CHECK SHALL BE HPPCL CHP

STAGE)

ITEM : GANTRY CRANE

SUB-SYSTEM :

MAIN-SUPPLIER

MAIN-SUPPLIER :

DOC. NO.


FOR HPPCL USE

PACKAGE :




Hydraulic Hoist Piping

QP NO.:

REV.01,

DATE:

SL.

NO.

ACTIVITY

AND

OPERATI

ON

CHARACTERISTICS /

INSTRUMENTS

CLASS

OF

CHECK

TYPE OF CHECKQUANTUM

OF CHECKREFERENCE DOCUMENTS

ACCEPTANCE

NORMSREMARKS

1 2 3 4 5 6 7 8 9 10

Piping & Sub components(tree/elbow/reducers etc.)

1 Overall Dimension/ location B Measurment 100% Drg. Log book

2


components B 100% Dispatch/received doc./drg Log book

3

Centering levelling &

alignment B 100% Drawing Log book

4 Assembly Fitment B 100% Drawing Log book

5 Field welding

a) butt weld A WPS/POR/qualified 100% ASME-IX Inspection record

b) DP test On butt weld A Rt on weld/DP test ( 100%

ASME-VIII/UW-51(VOLINEAR

INDICATOR Inspection record

6 Pressure testing for piping A

Measurment hydro

test 100%

As per drgs./data sheets as

per drgs./site req. Inspection record

7 Plate cut to size C Dim/Location 100% Log book

REVIEWED BY APPROVED B

FORMAT OF

RECORD

MANUFACTURER/

SUB-SUPPLIER


SUPP-

LIER'S

LOGO CONTRACT NO.:

SIGNATURE

LEGEND : *RECORDS IDENTIFIED WITH "TICK" (√ ) SHALL BEESSENTIALY INCLUDED BY CONTRACTOR IN QA DOCUMENTATION.

LEGEND TO BE USED: CLASS#: A=CRITICAL,B=MAJOR, C=MINOR;

'A' SHALL BE WITNESSED BY HPPCL FQA. 'B' SHALL BE WITNESSED

BY HPPCL ERECTION/ CONSTRUCTION DEPTT. AND 'C' SHALL BE

WITNESSED BY MAIN SUPPLIER (A & B CHECK SHALL BE HPPCL

CHP STAGE)

ITEM : Hydraulic hoist Piping

SUB-SYSTEM :

MAIN-SUPPLIER

MAIN-SUPPLIER :

DOC. NO.


FOR HPPCL USE

PACKAGE :




Legends

ITEM : Field quality Plan (Receipt & Storage) QP NO.:. ,

DATE:

Sheet

MANUFACTURER/SUPPLIER Main supplier

LEGEND: Records idemnified with "TICK() Shall be

essentially included supplier in QA documentation **

Manufacturer/Sub-Supplier C: Supplier/Nominated

Inspection Agency HPPCL HPPCL Doc No. Rev…..

For HPPCL use

Revised by Approved by Aprroval Seal

ENGG. DIVISON

CONTRACT NO.:

MAIN-SUPPLIER :

MANUFACTURERS NAME &

ADDRESS:

SIGNATURE


PACKAGE : HM Package




Receipt & Storage

QP NO.:

REV.0, DATE:

SL. NO. ACTIVITY AND OPERATIONCHARACTERISTICS

/ INSTRUMENTS

CLASS

OF

CHECK

TYPE

OF

CHEC

K

QUANTU

M OF

CHECK

REFERENCE

DOCUMENTS

ACCEPTANCE

NORMSREMARKS

1 2 3 4 5 6 7 8 9 D* 10

Second Stage embedded

parts for Diversion Tunnel

Roller Vertical Gate

A) Material Receipt

a) Check for shipping

list/ Packing

List/RRL/MDCC B Visual 100%

MDCC/CHP/shipping

Advice/RR/L/Drg Same as column Log book

b)Check for damage

& bend during

transportation B Visual 100% do do Log book

B) Material Storage

a)Stored in plain

open yard on raised

surface B Visual 100% do do Log book

b)Check for damage

& bend damageduring

loading/unloading B Visual 100% do do Log book

C) Ensure non confirming &

rejected components

identified A Visual 100% do do Log book



FOR HPPCL USE

DOC. NO. REV. ...

PACKAGE :

MAIN-SUPPLIER

FORMAT OF RECORD

SIGNATURE

LEGEND : *RECORDS IDENTIFIED WITH "TICK"

(√ ) SHALL BE ESSENTIALY INCLUDED BYCONTRACTOR IN QA DOCUMENTATION.

LEGEND TO BE USED: CLASS#:

A=CRITICAL,B=MAJOR, C=MINOR; 'A' SHALL


WITNESSED BYHPPCL ERECTION/

CONSTRUCTION

MANUFACTURER/

SUB-SUPPLIER

CONTRACT NO.:

MAIN-SUPPLIER :

SUPP-LIER'S

LOGO


ITEM :

SUB-SYSTEM :




Storage & Receipt

QP NO.:

REV: DATE:

Sheet

SL. NO.CHARACTERISTICS /

INSTRUMENTS

TYPE OF

CHECKCLASS

REFERENCE DOCUMENTS

& ACCEPTANCE

STANDARDS

QUANTUM /

FREQUENCY OF

CHECK

FORMAT OF

RECORDREMARKS

1 2 3 4 5 6 7 8

A

MATERIAL RECEIPT: (FOR

ALL ITEMS i.e. FABRICATION OF

PARTS : Ist STAGE EMBEDDED

PARTS ,IInd STAGE EMBEDDED

PARTS , CASING, GATE ELEMENTS

,LOCKING DEVICE ,GATE

PARTS,PIPES , VALVES

,HYDRAULLIC CYLINDER & POWER

PACK ,SEAL ,AIR COMPRESSER,etc.

LOOSE PARTS-NUTS & BOLTS

,PAINTS & LUBRICATION etc, FOR

RADIAL GATE (SPILLWAY &

BOTTOM OUTLET) VERTICAL GATE

,INTAKE,DRAFT TUBE & GANTRY

CRANE PARTS, HOIST PARTS

1

CHECK FOR THE AVAILABILTY OF

DOCUMENTS

VISUAL MAJOR

PACKING LIST/ LOADING

ADVISE SLIP

100%

2

VERIFY THE COMPONENTS /ITEMS

RECEIVED FOR FOLLOWING- A) LOOSE/OPEN

B) ITEM NO./Drg.NO.

VISUAL MAJORPACKING LIST/ LOADING

ADVISE SLIP

100%

3

CHECK THE COMPONENT /ITEN ON

RECEIPTFOR THE FOLLOWING

A) LOOSE/OPEN

B) PHYSICAL DAMAGE

C) SHAORTAGE /EXCESS OF QTY.

VISUAL MAJOR


ADVISE SLIP

100%

4

ENSURE NON-CONFIRMING &

REACTION COMPONENTS ARE

IDENTIFIED & STORED

SEPARATELY

VISUAL MAJORPACKING LIST/ LOADING

ADVISE SLIP

100%

5ENSURE CONTROL OF REEIPT &

ISSUE OF ALL THE COMPONENTSVISUAL MAJOR


ADVISE SLIP100%



FOR HPPCL

DOC. NO. REV. .

PACKAGE :

CONTRACT NO.:

MAIN-SUPPLIER :

MAIN-SUPPLIER

SIGNATURE

URER/

SUB-

ITEM: FIELD QUALITY PLAN (STORAGE &RECEIPT)

MANUFACTURER NAME &

ADDRESS




Storage & Receipt

FIELD QUALITY PLANQP NO.:

ITEN: FIELD QUALITY PLAN (

RECEIPT & STORAGE) FOR

KOLDAM HEPREV.0,

DATE:

Sheet 1of3

SL. NO. CHARACTERISTICS / INSTRUMENTSTYPE OF

CHECKCLASS

REFERENCE DOCUMENTS &

ACCEPTANCE STANDARDS

QUANTUM /

FREQUENCY OF

CHECK

FORMAT OF

RECORDREMARKS

1 2 3 4 5 6 7 8

A MATERIAL STORAGE :

1

FOR ALL ITEMS i.e. FABRICATION OF

PARTS : Ist STAGE EMBEDDED

PARTS ,IInd STAGE EMBEDDED

PARTS , LINEAR CASING, GATE

ELEMENTS,LOCKING DEVICE ,GATE

PARTS,PIPES , VALVES

STORED IN OPEN YARD ON RAISED

SURFACE PROPERLY CHECK FOR

MECHANICAL DAMAGE

VISUAL MAJORCHALLAN / INVOICE / MDCC

& NO DAMAGEONCE IN 3 MONTH

LG BOOK STORE

REGISTER

2

HYDRAULLIC CYLINDER & POWER

PACK CONTROL PANNEL, MOTOR ,

CABLES. G.I PIPE ,GANTRY CRANE

PARTS, SEAL,etc.

STORED IN OPEN YARD ON RAISED

SURFACE WITH TARPULAIN /PVC

COVER

VISUAL MAJORCHALLAN / INVOICE / MDCC

& NO DAMAGEONCE IN 3 MONTH

LG BOOK STORE

REGISTER

3 LOOSE PARTS-NUTS & BOLTS

,PAINTS & LUBRICATION etc.

TO BE STORED IN COVERED STOREIN RACKS/ BOXES WITH SUITABLE

TAGS

VISUAL MAJORPACKIND LIST CHLLANCHPS / MDCC & NO

DAMAGE

ONCE IN 3 MONTHLG BOOK STORE

REGISTER

REVIEWED BY APPROVED B

MAIN-SUPPLIER

SIGNATURE

URER/

SUB-

MANUFACTURER NAME &

ADRESS

PROJECT :

FOR HPPCL USE

DOC. NO. RE

PACKAGE : HM Package

CONTRACT NO.:

MAIN-SUPPLIER :

2011_12_Manual on Quality Assuarance and Quality Control(Civil Works and HM Works).pdf

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Transcript of 2011_12_Manual on Quality Assuarance and Quality Control(Civil Works and HM Works).pdf