Workmanship and Tests
During Construction
Phase
Presented by:
Er. Bhagawan Shrestha
Specification
• Definition:
A detailed description of the particulars of
some projected work in building, engineering,
or the like, giving the dimensions, materials,
quantities etc, of the work, together with
directions to be followed by builders or
constructor.
Back ground
• Prevailing Specification approved on July 2001
and enforced to use.
• Contains 31 sections including blank Section
300.
DOR SPECIFICATIONS
• SECTION 100 - GENERAL
• SECTION 200– SITE CLEARANCE
• Section 500 deals with QUALITY CONTROL
• Section 600 deals with MATERIALS AND TESTING OF MATERIALS
• Section 700 deals with PIPE DRAINS , PIPE CULVERTS AND
CONCRETE CHANNELS
• Section 900 deals with EARTHWORKS
Section 500 –Quality Control contains:
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501
502
503
504
505
506
507
508
509
510
511
SCOPE
CONTRACTOR RESPONSIBLE FOR THE
QUALITY OF THE WORKS
QUALITY CONTROL SYSTEM
QUALITY ASSURANCE PLAN
TESTING PROCEDURES AND SETS OF
TESTS
LABORATORY TRIALS
SITE TRIALS
CONTROL TESTING DURING CONSTRUCTION
ACCEPTANCE TESTS FOR COMPLETED
WORKS OR PARTS OF THE WORKS
SCHEDULE OF TESTS
LABORATORY
General
All materials incorporated and all
workmanship performed shall be
strictly in conformity with the
requirements of the Specifications and
the Contractor shall be responsible for
the quality of the works in the entire
construction within the contract.
Testing Procedures and Set of Tests
• For ensuring quality of work, materials and
workmanship be subjected to testing in
accordance with procedures, sets of tests and
frequencies as specified in Specifications
• Specified testing frequencies are not restrictive
• Engineer directs for the tests to be carried out as
frequently as deemed necessary
• Where no specific testing procedure mentioned
in Specifications, tests be carried out as per
prevalent accepted engineering practice or
directions of Engineer
Laboratory Trials
• Laboratory trials/mixes be carried out by
Contractor on materials proposed to be used
in works in their natural state.
• laboratory trials establish a relationship
between specified requirements of end
product and properties which can be
determined in field for purpose of
construction control.
Site Trials
• Materials, used for laboratory trial,
composition of which meets specified
requirements and is accepted by Engineer,
shall then be used in site trials
• Contractor shall submit the proposal for the
site trials to the Engineer at least two weeks
before
Site Trials(contd.)
• Site trials for laying and compaction
shall be carried out by Contractor
on all earthworks and pavement
materials proposed for works using
same equipment and methods
proposed for use in works.
Site Trials(contd.)
• Site trials for concrete mixes as specified shall be
carried out by Contractor to demonstrate
suitability of his mixing equipment. During site
trials, compliance with Specifications for weighing
equipment, storage of ingredients, means of
transport for concrete, placing, compaction and
curing shall be checked by Engineer. During the
site trial a full scale sequence including placing
and compaction of concrete shall be carried out
on a part of works which will represent particular
difficulties due to presence of reinforcement,
obstructions or others.
Site Trials(contd.)
Site trials demonstrates:
I. suitability of materials,
II. suitability of equipment for laying and
compacting materials to specified density,
and
III. confirmation of achievement of other
requirement of completed works.
Site Trials(contd.)
• Each site trial (for earthworks & pavement) to
be at least 100 m long and to full width and to
the specified depth of materials.
• Site trial be carried out at least 21 days ahead
of commencement of related works.
Site Trials(contd.)
Data to be recorded for each site trial:
i.
Composition and grading of material before site
trial,
ii. Composition and grading of material including
bitumen content,
iii. Moisture content at compaction and Optimum
Moisture content for that specified compaction,
Site Trials(contd.)
iv. Equipment details like type, size and tyre
pressures, frequency of vibration and
number of passes made by compaction
equipment,
v. Maximum dry density measured on sample
before site trials (Lab. Test),
vi. Density achieved,
vii. Compacted thickness of the layer
Site Trials(contd.)
• Contractor conducts 8 sets of tests on each
100m length of trial section for each level of
compaction effort.
• If all eight sets of results meet specified
requirements for material and workmanship,
site trial be deemed successful.
• Data recorded in trial becomes agreed basis
on which particular material be provided and
processed to achieve specified requirements.
CONTROL TESTING DURING
CONSTRUCTION
• All earthworks, pavement layers, and backfill to
drainage and other structures shall be subject to
control testing (process control) including, if
required, testing by the Engineer in accordance
with the Conditions of Contract and Clause 503.
• The tests to be carried out and their frequency
for the quality control of the works are detailed in
the relevant Sections of these Specifications
Testing Schedule (Example)
PART OR
Section/Clause
COMPONENT
No of
TESTS
FREQUENCY
OF THE
Specification
WORKS
700
PIPE DRAINS,
PIPE CULVERTS
AND CONCRETE
CHANNELS
MATERIALS
701
Identification : As specified
FOR RE-FILLING
Gradation,
or required by
THE TRENCHES
Plasticity
the Engineer
Index, CBR
In-Situ Density
(95% MDD)
Testing Schedule (Example)
EARTHWORKS
FILL
MATERIAL
COMPACTION
900
1. Material 1. For each
Identificati
new source
on, MDD,
and in
OMC,
every 1500
CBR
m3
2. MC
2. For each
new source
and in
every 250
m3
3. Field
3. One test
Density
per 250m2
of each
Acceptance testing
• Contractor requests, in writing for Engineer's
approval for each layer of each section of
earthwork, pavement construction and backfill
• Such request be accompanied by tests results
required by Specifications.
• Engineer inspects section for any visible defects
including, heaving material (visible during
compaction), segregation, and for uniformity of
mixing and compaction
Acceptance testing (contd.)
• If visual aspects satisfactory Engineer tests
Section of works submitted and informs
Contractor in writing of results of tests
specifying acceptance or rejection of section
or layer concerned
• Work on a layer in no circumstances
commences until preceding layer been
approved and accepted by Engineer in writing.
Acceptance testing (contd.)
• Contractor fully responsible for protecting and
maintaining condition of work submitted for
approval.
• any layer left unprotected for more than 24 hours
subsequent to approval shall again be subject to
construction control testing, and tolerance
checks.
• Contractor responsible for making good any
subsequent damage due to traffic, ingress of
water or any other reason
Section 600 contains
• 601 SCOPE
• 602 QUALITY OF MATERIALS
• 603 SOURCES OF MATERIALS
• 604 INSPECTION AND ACCEPTANCE OF MATERIALS
• 605 MATERIALS AND MANUFACTURED ARTICLES
• 606 DEFECTIVE MATERIALS
Section 600
Table 6.3 : Classes of Material Quality
MATERIAL
LAA
AIV
CLASSES
%
SSS Degradabilit Flakiness Crushin
y
g
Test
Test
Index
Ratio
%
%
%
<12
<5
<20
100
<12
<5
<25
100
<12
<5
<25
80
A
B
C1
<25
<30
<35
ACV
%
<20
<20
<25
C2*
D1
<30
<40
<20
<30
<12
<12
<5
<5
<25
<30
60
D2*
E1
E2
E3
<35
>35 & <50
>40 & <50
>50
<20
<25
<30
<30
<12
<18
<18
<18
<5
<10
<10
-
<30
-
-
C
D
E
Table 6.4:
Tests Procedures Applicable to
Disturbed/Undistributed
Samples of Soils and Gravels
Tests
Test procedure
Determination of :
i) Moisture Content
IS 2720
Part 2 (Oven-drying method)
ii) Liquid Limit
IS 2720
Part 5 (Cone Penetrometer or by Casagrande Apparatus)
ApparatusaP
iii) Plastic Limit
IS 2720
Part 5
iv) Plasticity Index
IS 2720
Part 5
v) Linear Shrinkage
IS 2720
Part 20
vi) Specific Gravity of Particles
IS 2720
Part 3
vii) Particle Size Distribution
IS 2720
Part 4
viii) Organic Matter Content
IS 2720
Part 22
ix ) Total Sulphate Content
IS 2720
Part 27
x) pH Value
IS 2720
Part 26 (Electrometric Method)
xi) Mica Content
xii) Density-Moisture Content relationship
(2.5 kg rammer)
-
Manual mineralogical counting
IS 2720
Part 7
xiii) Density-Moisture Content relationship IS 2720
(4.9 kg rammer)
Part 8
xiv) California Bearing Ratio
IS 2720
Part 16
xv) Sand Equivalent
IS 2720
Part 37 (Mechanical Shaker or Manual Shaker method)
xvi) Field Dry Density
IS 2720
Part 28/Part 29
xvii)
Unconfined compression test
IS2720
Part 10
xviii)
Consolidation test
IS2720
Part 15
xix)
Direct shear test
IS2720
Part 13
xx)
Triaxial test
IS2720
Part 11,12
xxi)
Hydrometer analysis
IS 2720
Part 4
xxii)
Vane shear test
IS 2720
Part 30
Table 6.5 :
Tests Procedures Applicable to
Stone Aggregate and Fillers
Tests
Test Procedure
Determination of:
i)
Particle Size Distribution
IS 2386
Part 1
IS 2386
Part 2
iii) Flakiness Index
IS 2386
Part 1
iv)
Specific Gravity
IS 2386
Part 3
v)
Moisture Content
IS 2386
Part 3
vi)
Bulk Density,Voids & Bulking
IS 2386
Part 3
vii)
Soluble Chloride Content
BS 812
Part 117
(Gradation)
ii)
Clay, Silt, Dust in Aggregates
viii) Mica Content
Manual mineralogical counting
ix)
Water Absorption
1S 2386
x)
Crushing Ratio
Manual counting & weighing
xi)
Los Angeles Abrasion
IS 2386
Part 4
xii)
AIV - ACV
IS 2386
Part 4
xiii) Polished Stone Value
IS 2386
Part 4
xiv) Degradability Test
NFP 94 - 067
xv) Sodium Sulphate Soundness
IS 2386
Part 5
xvi) Alkali Aggregate Reactivity Test
IS 2386
Part 7
xvii) Bitumen Adhesiveness (Vialit
NFP-98-274-1
Part 3
Test)
xviii) Deleterious Substances
IS 2386
Part 2
xix) Sand Equivalent
IS 2720
Part 37
Table 6.11: Tests Procedure Applicable
to Straight run Bitumen
Tests
Determination of :
i) Penetration
ii) Softening point (Ring and Ball)
iii) Flash and fire points ( open cup)
iv) Loss on heating
v) Ductility
vi) Water Content
vii) Solubility in Trichloroethylene
viii) Specific gravity
ix) Penetration of residue from loss
on heating
Test Procedure
ASTM D 5
ASTM D 36
ASTM D 92
ASTM D 6/D1754
ASTM D 113
ASTM D1461/D95
ASTM D 2042
ASTM D70
ASTM D5
Table 6.12: Tests Procedure Applicable
to cutback Bitumen
Tests
Test Procedure
Determination of :
i) Kinematic viscosity
ii) (a) Flash point (Tag open cup) (RC-MC)
(b) Flash point ( open cup) (SC)
iii) Penetration
iv) Specific gravity by hydrometer method
v) Asphalt residue of 100 pen (SC)
vi) Water content
vii) Distillation
viii) Penetration of residue from distillation
ix) Ductility of residue from distillation
x) Solubility of residue from distillation
ASTM D 2170
ASTM D 3143
ASTM D 92
ASTM D 5
ASTM D 3142
ASTM D 243
ASTM D 95
ASTM D 402
ASTM D 5
ASTM D 113
ASTM D 2042
Table 6.13: Tests Procedure Applicable
to Bitumen Emulsion
Test
Determination of :
(i) Residue on 0.710 mm sieve
(ii) Residue on 0.150 mm sieve
(iii) Stability to mixing with coarse
(iv) aggregate
(v) Stability to mixing with cement
(vi) Binder content
(vii) Engler viscosity
(viii) Redwood II viscosity
(ix) Storage stability (short period)
(x) Storage stability (long period)
Particle charge
Test Procedures
BS 434 Part I, Appendix C1
"
"
"
C2
"
"
"
D1
"
"
"
D2
"
"
"
E
"
"
"
F1
"
"
"
F2
"
"
"
H1
"
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H2
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"
J
Table 6.6: Requirements on the Physical Characteristics of Cement
S.N.
Physical characteristics
i)
Fineness, m2/kg: (by Blaine's Air
Permeability method)
ii)
Setting Time :
OPC /
PSC
HSPC Test Procedure
225
225
(a) Minimum Initial Setting Time
(minutes)
45
45
(b) Maximum Final Setting Time
(minutes)
600
600
10
10
iii) Soundness by Lechatelier method, mm,
maximum
IS-4031
Part 2
IS 4031 Part 5
IS 4031 Part 3
iv) Compressive Strength :
Minimum Average Compressive
Strength of three mortar cube(N/mm²)
(a)
3 days
16
27
(b)
7 days
22
37
33
53
(c)
28 days
IS 4031 Part 6
CONCRETE
The minimum frequency of sampling of concrete of each grade shall
be as following:
For 1-5 m3 quantity of work
- 1 no. of sample
For 5-20 m3 quantity of work
- 2 no. of sample
For 20 m3 and more quantity of work - 3 no. of sample plus one
additional for each 20m3 or part thereof.
At least one sample shall be taken from each shifts of work.
Table 6.14: Specification for Straight run Bitumen
S.N.
Specifications
Penetration Grade
60/70
80/100
180/200
i)
Penetration, at 25°C (100g-5s), in 0.1 mm
60-70
80-100
180-200
ii)
Softening point (Ring and Ball), °C
44-54
41-51
33-42
iii)
Flash point ( open cup), °C (min)
250
225
200
iv)
Ductility at 25°C, cm (min)
100
100
100
v)
Loss on heating (5 h at 163°C) % (max)
0.2
0.5
0.5
vi)
vii)
Penetration of residue from loss on
heating at 25°C (100 -5s) % of initial pen
80
80
80
(min)
Specific Gravity at 25°C
1.01-1.06 1.00-1.05 1.00-1.05
viii)
Water, % by weight (max)
0.2
0.2
0.2
ix)
Solubility in tricloroethylene, % by weight
(min)
99.0
99.5
99.5
The number of tests and criteria for conformity shall be as per IS 73.
Table 6.15: Tests Procedure Applicable
to Bituminous Mixtures
Tests
Test Procedure
Determination of :
i) Moisture and volatile distillates
ASTM D 1461
ii) Quantitative extraction of bitumen
ASTM D 2172
iii) Specific gravity of compacted mixture
ASTM D 1188 & D 2726
iv) Recovery of bitumen from solution
ASTM D 1856
v) Coating and stripping
ASTM D 1664
vi) Degree of particle coating
ASTM D 2489
vii) Maximum specific gravity
ASTM D 2041
viii) Degree of pavement compaction
AASHTO T230
ix) stability
ASTM D1559
2401
GABIONS
• Gabions shall consist of steel wire mesh crates.
Steel wire shall be mild steel wire complying with
NS 169-2045.
• Weight of deposition of zinc shall be in
accordance with NS 163-2045. Zinc coating shall
be uniform and be able to withstand minimum
number of dips and adhesion test specified as per
NS 163-2045
• Wire shall be woven into hexagonal mesh with
minimum of 3 twists
2401
GABIONS (Contd.)
• Selvedge wire at least 3 gauges heavier than
mesh wire
• Gabion wire shall be tested for mass,
uniformity and adhesion of zinc coating and
tensile strength of the wire itself.
Section 1200 (Contd.)
• 1201 MECHANICALLY STABLE SUBBASE CONTAINS:
1.
Scope
2.
Sources of Materials
3.
4.
Material Requirements- (a) Gravel , (b) Sand, Silty and Clayey
Sands, (c ) All Materials
Compaction Trials
5.
Laying and Compaction
Section 1200 (Contd.)
6.
Proof Rolling
7.
Setting out and Tolerances
8.
Drainage of Subgrade and Subbase
9.
Testing – (a) Process Control, (b) Routine Inspection and Testing
10. Measurement
11. Payment
Mechanically Stable Sub base
(Example)
Table 12 .2 : Minimum Testing Frequency
Tests
Materials:
Gradation
Plasticity Index
Maximum Dry Density and
Optimum Moisture Content
Workmanship:
Field Density and Moisture
Content
Construction Tolerances:
Surface Levels
Thickness
Width
One test in every
200 m3 or part of it and change in source
"
"
"
"
1000 m3 "
"
"
Min. no of tests
per section
2
2
2
500 m2
2
10 m
25 m
200 m
-
Construction & Workmanship Tests
• Earthwork in cutting/Sugrade
a) Detern of Insitu MC
b) Detern of Insitu Density
c) Horizontal Alignment
d) Surface Level
e) Surface regularity
Construction & Workmanship Tests
• Granular Sub base
a) Gradation of In situ materials
b) LL/PL –PI of In situ materials
c) AIV of In situ materials
d) Detern of In situ MC
e) Detern of In situ Density
f) Compacted thickness
g) Horizontal Alignment
h) Surface Level
i) Surface regularity
• Construction Control Testing/Process Control
Testing
Unless otherwise directed, values given in these
Specifications are minimum values for the
properties of materials and the workmanship.
They shall be considered satisfactory, if all results
of the tests, taken at the frequencies specified,
are at least equal to the values given in the
relevant Section of these Specifications
THE END
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