quality assurance plan sparco for sulemanki.pdf

8/11/2019 Quality Assurance Plan Sparco for Sulemanki.pdf

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Rehabilitation & Upgradation of Sulemanki Barrage Quality Assurance Plan

TABLE OF CONTENTS

Sr. No. Description

PREFACE

ABBREVIATIONS

Section-1. QUALITY ASSURANCE ACTIVITIES

1.1. Contractors Submittals

1.2. Earthwork

1.3. Concrete Work

1.4. Bored Cast-In-Situ R.C.C. Piles

1.5. Pile Load Test

1.6. Stone Pitching & Stone Apron1.7. Brickwork

1.8. R.C.C. Pipes & Laying

1.9. Steel Sheet Piles

Section-2. QUALITY CONTROL/QUALITY ASSURANCE TESTING

2.1 Types of Material Tests

2.2 Testing Arrangements/Equipment

2.3 Testing Requirements

Section-3. RECORD/REPORTING DOCUMENTS

3.1 Laboratory Record/Reporting Documents

3.2 Field Record/Reporting Documents (Field Inspection/Testing)

Section-4. SAFETY REQUIREMENTS

Section-5. STANDARDS & PROCEDURES


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PREFACE

This Quality Assurance Plan (QAP) is an effort to outline the activities of the Contractor

in adequate details for the guidance of its staff and other relevant Personnel, during the

construction activities of the project to satisfy the requirements of Contract. It requires

that individuals have clearly defined responsibilities and lines of communication to enable

all aspects of the work activities to be assessed and accepted and if a problem is discovered,

the solution is quickly found. QAP cannot replace the experience of reasonable and

responsible staff; however it can help them in selection of timely and sequential line of

various activities and in keeping and maintaining retrievable record documentation. This

QAP is specially designed for Rehabilitation and Upgrading of Sulemanki Barrage

Project

The Contractor is, in particular, responsible for the Quality Control of the Works as per

Contract Specification . Consultants supervision and surveillance does not relieve the

Contractor of his contractual obligations. The basic purpose of QAP is to ensure that the

Quality Control System is in place and performing to the requirements of Contract

documents, during the construction period.

The quality requirements are based on provisions for technical specifications as per

contract documents for R&U of Sulemanki Barrage. Maximum efforts have been exerted in

making QAP an acceptable and tangible document for all levels of execution and supervisory

staff and novice to experience. Technical notes are provided at places to develop field staffs

approach and insight for a useful and effective supervision, without undermining adherence

to the contract specification.

The Contract Documents are the basis for this QAP, therefore, where an ambiguity is

detected between the procedures and requirements of QAP and content of Contract

Documents then the latter takes the precedence.


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The following are the objectives while formulating QAP.

To define and adopt a sequential and systematic quality assurance line of action with

participation of the other stake holders for ensuring of all submittals, procurement,

execution of works and other on and off site construction activities. These activities mayalso include material supply, testing and reporting envisaged in the specification of the

project.

To maintain auditable record of all tests, inspections, procedures and corrective

measures and any other information considered helpful.

To define the assignment and responsibilities of the Contractors field staff and other

relevant personnel at site with respect to Quality Assurance of the project viz a the

Contractors Quality Control Programme and their interaction with the client and the

Consultant.

To prevent non-conformities through proactive Quality Assurance.


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ABBREVIATIONS

A.C.I. American Concrete Institute

A.R.E. Assistant Resident Engineer

AASHTO American Association for State Highway and Transportation

Officials

ASTM American Society for Testing Material

B.S. British Standards

C.M.E. Construction Management Engineer

C.R.E Chief Resident Engineer

E.R. Engineers Representative (Consultants)

FR Field Record Document (Inspection Note/Testing etc.)

Geotech. Engr. Geotech Engineer

Insp. Inspector

The Engineer Consultants

LOA Letter of Acceptance

LR Laboratory Record (Testing etc.)

M.E Material Engineer

NSL Natural Surface Level

P.M Project Manager

PD PMU Project Director (Clients Representative)

PIDA Punjab Irrigation & Drainage Authority

PMU Project Management Unit

Q.C.S. Quality Control Section

(Geotech/Mat. Engr. + Field Lab.)

R.E Resident Engineer

SOP Survey of Pakistan

TBM Temporary Bench Mark


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1.1 CONTRACTORS SUBMITTALS

1.1.1 Objective

The objective of this Section is to guide the field staff of the Contractor regarding different

submissions to be made in the form of check requests, test requests, approval requests and

authorization requests for execution of work. These submissions will be made by for

methodological construction execution works.

1.1.2 Applicability

The Contract Documents for R&U of Sulemanki Barragerequire the Contractor to submit

certain documents to the Consultants, i.e. before, during and after the execution of the

works. These documents / write-ups may include;

Work Programmes (As per Contract specifications)

Quality Control Test Results (As per Contract specifications)

Drawings and data for Equipment (As per Contract specifications)

Installation Instructions for Equipment (As per Contract specifications)

Operation and Maintenance Manual for mechanical equipment (As per Contract

specifications)

Manufacturers Certificates for various Construction Materials like water stops,

bearing pads, expansion joint fillers and sealants.

The submittals for various items of Project Works are provided in the checklist CKL-1.1

Checklist for Contractors Submittals for the guidance of the Contractorsfield staff.


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CKL 1.1 (1) CHECKLIST FOR CONTRACTORS SUBMITTALS

General

Sr. No. Submittal Document Format Time For Submission

1.1 Contractors workProgramme including

arrangements, order and

timings

Contractors Format

As per Specification

Within 28 days of delivery

of LOA and updates when

required

1.2 Details of the

Programme andResource Schedule

Contractors Format

As per Specification

Within 28 days of delivery

of LOA

1.3 Request for Survey

check by the Contractor

Contractors Format Prior to commencement ofworks

1.4 Contractors Quality

Control Programme

Contractors Format Prior to commencement of

works

These submissions shall be made by the Contractor to The Engineer for prior review,who shall forward these to the Consultants for detailed review and agreement/advice.


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Earthworks and Caring & Handling of Water


2.1 Plan for Protection and

Diversion Works*

Contractors Format Prior to Construction of

protection and diversion

works

2.2 Plan for Dewatering of

foundations to be

submitted direct to The

Engineer

Contractors Format Prior to Commencement

of dewatering operations

2.3 Materials SourceApproval*

Contractors Format Prior to commencement

of component of work

2.4 Quality Control/

Assurance Tests to be

submitted direct to The

Engineer

Consultants QAPSpecified Formats

As per requirements of

specifications and QAP

2.5 Job Safety Analysis as

per HSE requirements

Contractors Format Prior to start

Construction

*These submissions shall be made by the Contractor to The Engineer for detailed review

and agreement/advice.


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Concrete Works


3.1 Method Statement ContractorsFormat Prior to Construction

3.2 Mill test Certificates for

Steel Reinforcement

ManufacturersFormat

Along with delivery of steel

at site

3.3 Bar Bending Schedule FR-06 3 days Prior to

Commencement of

fabrication of Re-Steel

3.4 Quality Control Tests for

Concrete works

Consultants QAP

Specified Formats.

As per requirements of

specifications and QAP

3.5 Manufacturers

Certificate for Rubber

water stops, bearing

pads joint filler and

sealants

Manufacturers

Format

Prior to procurement

3.6 Job Safety Analysis as

per HSE requirements

Contractors Format Prior to start Construction

These submissions shall be made by the Contractor to The Engineer for detailed review



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Bored Cast-in-Situ R.C.C. Piles


5.1 Method Statement Contractors Format

As per Specifications

Prior to commencement

of work

5.2 Date of Survey and

Location

Contractors Format Prior to commencement

of work

5.3 Protective Measures Contractors Format Prior tocommencement of

work

5.4 Placement Schedule Contractors Format Prior to commencement

of work

5.5 Approval for Source of

Material

Contractors Format Prior to commencementof work

5.6 Pile Construction Record QAP Format Within 24 hours of

completion

5.7 Quality Control Tests QAP Specified Format Within 24 hours of the

completion of Tests

5.8 Job Safety Analysis Contractors Format Prior to commencement

of work

These submissions shall be made by the Contractor to The Engineer detailed review and

agreement/advice.


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Pile Load Test


6.1 Method Statement Contractors Format Prior to commencement of

Test

6.2 Calibration Certificate

for Test Apparatus

Contractors Format Prior to commencement of

Test

6.3 Pile Construction

Record

QAP Format Within 48 hours of

completion of pile

construction

6.4 Pile Load Test Record

and Report

Contractors Format As soon as possible after

completion of the Test.

6.5 Job Safety Analysis Contractors Format Prior to commencement ofwork




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Mechanical Equipment


7.1 QAP Contractors Format After 28 days of

Commencement of Works

7.2 Work Schedule, Method

Statements & List of

Contractors submittals

Contractors Format After 28 days ofCommencement of Works

7.3 Request for Approval ofSub-contractor for M & E

Works

Contractors Format Prior to procurement ofGates and Hoists

7.4 Design calculations &

Shop Drawings for

Mechanical & Electrical

Plants

Contractors Format Prior to start of

fabrication of each

component of work

7.5 Manufacturers Schedule& Method Statements

Contractors Format Prior to start offabrication of each

component of work

7.6 Installation Schedule and

Detailed Procedure

Contractors Format At start of each

component of work

7.7 Operation and

Maintenance Manual

Contractors Format When gates and gearings

have been installed

7.8 As Built Drawings Construction

Drawings

45 days after Certificate of

Completion

7.9 Job Safety Analysis Contractors Format Prior to commencement

of work




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1.2 EARTHWORK

1.2.1 Objective

Objective of this Section is to provide the recommended guidelines to the Contractors field

staff for their guidance in performing quality assurance of earthwork for structures and for

the canal embankments etc. pertaining to the Permanent Works

This Section covers the open cut/foundation excavations, foundation backfills for the

structures and earthwork for irrigation canal embankments. The recommended guidelines

can also be used for other similar works and earthwork required for diversion

arrangements.

1.2.2 Construction Equipment

Selection of type of excavation and compaction equipment must be done wisely keeping in

view the bulk of work and efficiency of the equipment and that the selected equipment is

capable and adequate to perform the required earthwork. The following may be deployed as

per the nature of work involved;

Excavators

Dozer and Rippers

Tractors with implements

Front End Loaders

Dragline Excavators / Cranes

Dump Trucks

Motor Graders

Water Bowser

Dewatering Arrangements Compactors(Rollers)

Flood Light Arrangements

1.2.3 Inspection

Setting out details on site as per design will be the responsibility of the field staff.

The Consultants through their own field staff shall check the setting-out accuracy,

survey control for NSL and design levels by joint survey with Contractor. These

surveys shall be carried out by Contractors surveyors in the presence of


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Consultants Inspectors. The site inspector .shall monitor the excavation slopes for

stability and compaction of the sub grade and fills, etc.

If the Contractor encounters wet or slush, he is required to report to the Consultants

Site Engineer who will jointly inspect the site, evaluate according to Earthwork SubClause of Technical Specifications of Contract Documents and submit their

recommendations for approval by the Engineer.

The Control of moisture and compaction of soils in the embankment of canals and

compacted earth consists of inspection of the material used, checking the amount

and uniformity of the soil moisture, maintaining the thickness of layer, and finally

determining the percentage of relative Dry Density of the compacted fill.

The relative Dry Density of the compacted fill is determined on the basis of FieldDensity Tests and the Reference Laboratory Compaction Tests. The Field Density

Tests shall be performed by the Contractors staff as and when directed by the

Engineer In-charge or Site Inspectors.

Tests at critical areas shall be carrying out by Consultants staff and verified in

Consultants Field Laboratory.

The Standard/Modified Proctor Compaction Tests are used as Reference Laboratory

Tests for fine grained clayey soils. These tests shall be performed at the ContractorsField Laboratory.

The Maximum and Minimum Dry Density Test results (from external laboratory) are

used as Reference Laboratory Tests for cohesion less sandy soils.

The soils having less than 12% passing No. 200 sieve are defined as sandy or non-

cohesive soils.

The Site Inspector should see that all perishable matter and any soil which may

become unstable upon saturation, such as highly organic soils, loose silts, very fine

sands/silts and expansive clays etc. are not present in the foundations. These soils

either need to be removed or improved to the extent necessary to provide a safe,

stable foundation or sub-grade under operating conditions.

A good bond between the foundation and first layer of fill is achieved by moistening

the foundation rather than using a very wet embankment layer.

For Quality Assurance (QA) of earthwork operations the Staff shall proceed in

accordance with CKL-1.2(1) Checklist for Structural Excavations and CKL-1.2(2) Checklist for Canal Earthworks.


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An important function of inspection is to determine when and where to make Field

Density Tests. These tests should be made in areas where degree of compaction is

doubtful.

Areas of doubtful density are sometimes detected by observation. Possible locations

of insufficient compaction include:

The junction between areas of mechanical tamping and rolled earth fill

embankment along abutments or cut-off walls.

Areas where rollers turn during rolling operations.

Areas where too thick a layer is being compacted.

Areas where improper moisture content exists in the soil.

Areas where less than specified number of roller passes were made.

Areas where oversized rock which has been overlooked, is contained in the

fill.

Areas containing material differing substantially from the average.

1.2.4 Specified Limits for Degree of Compaction

While performing control over compaction the limits given below from specifications should

be observed.

Compaction Requirements

Description Cohesive Soils Cohesionless Soils

Backfill around Structures

above foundation level90% Modified Proctor Dry Density 70% Relative Density

Special Backfill and Fill

beneath Structures

(Foundations)

95% Modified Proctor Dry Density 80% Relative Density

Foundation under Canal

Embankment / Sub-grade

for Lining

90% Modified Proctor Dry Density 70% Relative Density

Canal Embankments

(Main or Branch)90% Modified Proctor Dry Density 70% Relative Density

Disty/Minor

embankments90% Modified Proctor Dry Density 70% Relative Density


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1.2.5 Frequency of Control Tests

The recommended tests, their procedures, frequency and the required facilities for an

effective quality control/assurance of earthwork are presented in Section 2.3 Testing

Requirements. The contractors field staff is required to ensure that these tests are

performed as per specified frequencies in the recommended laboratories or at site. The field

tests should be performed in the presence of the Engineers site Inspector and the results

recorded immediately on completion of the test, duly signed by the authorized

representative of the Contractor and Consultants. An independent record of the tests

should also be maintained by consultants field staff, in addition to the submittals of the

Contractor.

1.2.6 Safety

The Contractor is to ensure and monitor compliance of the requirements of the Law of

Pakistan for safety, health and environment impact, in the domain of the construction

contract. For safety check proceed in accordance with CKL-5.1 Safety.


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CKL 1.2 (1) CHECKLIST FOR STRUCTURAL EXCAVATIONS

Sr.

No.Issues Action by

Record/Reporting

Document

1. Level of TBMs established by theContractor, Confirm by Survey Control.

Engineers Rep.

Contractors

Surveyor

Survey & Level

Book and FR-02

2. NSL by checking of the survey data andrecord entries. Check and approve by

Survey Control.

3. Complete setting out/layout. Check by

Survey Control and Dimensional

Inspection.

4. Location and level of level pegs, Checkby visual inspection and Survey

Control.

5. Location of spoil or dump for excavatedmaterial. Optional Check by Visual

Inspection.

Lab TechnicianFR-02

6. Deployment of proper Equipment.Discuss with Contractor and Ensure.

Lab TechnicianFR-02

7. Adequate dewatering to desired levels,before start of excavation below water

table. Water level to be maintained 3 ft.

below the lowest foundation level.

Ensure by physical inspection

Lab Technician

FR-02

8. Complete information about conditionof soil i.e. dry, wet or slush. Check by

physical inspection and record

observations.

Lab Technician

FR-02

9. Stability of excavated slopes. Ensure byphysical inspection.

Lab TechnicianFR-02

10. Final levels of excavated surfaces andrecord entries. Check by Survey Control

and make record entries.

Engineers Rep.

Contractors

Surveyor

Survey & Level

Book and FR-02

All actions should be taken in accordance with the Contract Specifications and Contractors

Work Methodology as approved by the Engineer.


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CKL 1.2 (2) CHECKLIST FOR CANAL EARTHWORKS

Sr.

No.Issues Action by

Record/Reporting

Document

1. Level of TBMs established by theContractor to be checked jointly.

-Engineers Rep.

-ContractorsSurveyor

Survey & LevelBook and FR-02

for comments

2. NSL by checking of the survey data andmake record entries by Joint Survey.

3. Complete setting out/layout. Check bySurvey Control and Dimensional

Inspection.

4. Location and level of level pegs, Checkby spot visual inspection and Survey

Control.5. Final levels of excavated surfaces.

Check by Survey Control.

6. Deployment of proper equipment.Discuss with Contractor and Ensure

Lab Technician FR-02 for

comments

7. Clearing, Grubbing and Stripping.

Ensure by physical inspection.

Lab TechnicianFR-02

8. Approval of backfill material(excavated or borrowed). Check by

physical Inspection or Test Procedures.

Lab Technician Field

Lab. FR-02/Letter

LR-01, 03

9. Compaction control during executionCheck by physical Inspection and Test

Procedures.

Lab Technician FR-03/A, FR-

03/B, FR-03C,FR-

02, LR-05

10. Records of all Tests made during timeperiod. Update periodically.

Lab Technician FR-04

FR-05

LR-05




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1.3 CONCRETE WORK

1.3.1 Objective

Objective of this section is to provide the recommended guidelines, sequential

inspection procedures and other relevant information to the field staff of the

Contractor for their guidance in quality assurance of reinforced concrete and pre-

stressed concrete pertaining to the permanent works being executed at site.

1.3.2 Applicability

This section covers Plain Cement Concrete (P.C.C.) the Reinforced Cement Concrete

(R.C.C.) and pre-stressed concrete works for permanent structures as well as pre-

cast works as shown on the drawings and as directed by the Project Manager.


The Contractor must ensure that the equipment is adequate to perform the concrete

work.

1.3.4 Inspection

1) For quality assurance of construction activities the Consultants Supervisory

Staff shall proceed in accordance with CKL-1.3 (1) Checklist for concrete

work.

2) For effective Quality Control, the Contractor is required to perform certain tests

at different stages of the concreting process. These tests include tests to be

performed on concrete ingredients, before start of the concreting works, tests to

be performed during construction stages and the tests to be performed

subsequently in the Contractors Field Lab. or in any other approved externallaboratory.

3) A list of tests, the test procedures, test frequencies and the proposed testing

arrangements are provided inSection 2.3 Testing Requirements.

4) The required Record/Reporting Documents for the Consultants Field Staff are

also listed in Section 2.3 Testing Requirements.

5) To maintain an auditable and retrievable record of all Inspection Tests, Non-

compliance and Corrective Actions etc. the provided proformas must be used by

the Consultants Supervisory Staff.


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6) The Engineer is to ensure that the required tests are performed by the

Contractor in accordance with the specified procedures and in the presence of

his representative. He is required to maintain a complete record of these test

results independently.

1.3.5 Classes of Concrete

Concrete for several structures and part thereof shall have 28-day compressive

strength of 6 12 cylinders at least equal to the minimum allowable strength

shown in the following Table:

Class Nominal Mix*Compressive Strength at 28-days

Cylinder Strength

A 1:1:2 5000 Psi

A 1:1 :3 4000 Psi

B 1:2:4 3000 Psi

C 1:2.5:5 2500 Psi

D 1:3:6 2000 Psi

E 1:4:8 1200 Psi

* Actual Mix Ratio will be determined after Concrete Mix Design carried out in accordance

with relevant Sub-Clauses of Technical Specifications of Contract Documents.

1.3.6 Concrete Slump

For various structural components the concrete shall have the following slump:

Class Structural Component Slump

A Pre-cast concrete 2 to 4

B Concrete Piles 5 to 7

C Canal Lining 1 to 3

C Cut-off Walls 2 to 4

B and CGeneral Reinforced Concrete for Bridge & other

Structures2 to 4

C Plain Concrete 2 to 4

D Fill Concrete 2 to 4

E Blinding/Lean Concrete 2 to 4


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1.3.7 Nominal Maximum Aggregate Size

The nominal maximum aggregate size to be used in various structural components

shall be as follows: (Technical Specifications 5.2)

General Use Nominal MaximumAggregate Size

Blinding/Lean Concrete and Canal Lining "

Maximum dimension of Structure less than 12 "

Maximum dimension of Structure more than 12 1

1.3.8 Concrete Mix Design

The mix proportions for class of concrete mentioned in the specifications are

nominal. The concrete mix design is required to be carried-out by the contractor

under supervision of Engineers representative at field laboratory using cement,

sand and aggregates from the approved source of supply.

Required average strength fcr used as the basis of selection of concrete proportion,

shall be in accordance with ACI 318 and provided in the under mentioned Table.

Specified Compressive Strength fc(PSI) Required Compressive Strength f cr

(PSI)

Less than 3000 f c +10003000 to 5000 f c +1200

Over 5000 f c +1400

The concrete mix design for each class of concrete in addition to mix proportion will

also provide water-cement ratio by weight (exclusive of water absorbed by the

aggregate) which will be determined on the basis of producing concrete having

suitable workability, density, impermeability, durability and the required strength.

1.3.9 Concrete Pour Authorization

The contractor is required to submit two copies in two different colours (white and

pink) of Concrete Pour Authorization (CPA) Request Form FR-07 before starting

concrete for any component of a structure. The Engineer should check all the items,

before allowing pouring of concrete. In case of deficiency, that would be marked on

the CPA slip and returned to the Contractor for rectification. The same CPA slip will

be finally signed on satisfactory rectification. Pink copy will be


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retained by the Engineer for reference and record. Contractors copy (white) should

be kept at site by the Contractor.

1.3.10 Safety

Proceed in accordance with CKL-5.1 Safety.


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CKL 1.3 (1) CHECKLIST FOR CONCRETE WORKS

Sr.

No.Issue Action by

Record/Reporting

Document

1. Physically inspect all theReinforcement Steel procured by the

contractor and confirm adherence to

the Specifications by Test Procedures.

Lab Technician ManufacturersCertificate and/or

External Lab.

Format.

2. Physically inspect, cement procured by

the contractor and confirm adherence

to the Specifications by Test

Procedures.

Lab Technician Manufacturers

Certificate and/or

External Lab.

Format.

3. Physically inspect, fine and coarse

aggregates and confirm adherence to

the Specifications by Test Procedures.

Lab Technician Ref. Section 2

4. Deployment of proper equipment.Discuss with Contractor and Ensure

Lab Technician FR-02 forcomments.

5. Receive Concrete Pour Authorization

C.P.A. Request from the contractor.


6. Check all items of C.P.A. as per

requirements of specifications and

Drawings and approve.


7. Mixing, Transportation and Pouring of

Concrete. Check by Physical Inspection

and Test Procedure.


8. Compressive Strength of ConcreteCylinders. Check by Test Procedures.

Lab Technician. Ref. Section 2FR-09, LR-07

9. Record of all Tests made during the

period. Update Periodically.

Lab Technician. Ref. Section

FR-10

All actions should be taken in accordance with Contract Specifications and Contractors work

methodology as approved by the Engineer.


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1.4 BORED CAST-IN-SITU R.C.C. PILES

1.4.1 Objective

Objective of this Section is to provide the recommended guidelines, sequential inspection

procedures and other relevant information to the field staff of the contractor, for their

guidance in performing Quality Assurance of Bored Cast-in Situ R.C.C. Piles for Structures

pertaining to the Permanent Works, being executed.

1.4.2 Applicability

This Section covers the construction of bored Cast-in-Situ R.C.C. Piles for Pile Load Tests,

and Working Piles for various Structures, pertaining to the Permanent Works being

executed by the Contractor.


The Contractor must ensure the adequacy of the deployed equipment for performing

the job.

1.4.4 Inspection

The field staff is required to ensure setting-out accuracy, perform survey control for

NSL and design levels. The required surveys are carried out by the Contractors

Surveyors along with the Engineers representative.

Each Pile shall be placed with its top being within 2 inches (50.8 mm) of the correct

position as shown on the Drawings.

Pile shall be cast as accurately as possible to the vertical. The maximum allowable

deviation from the vertical shall not exceed 0.5 degrees (1:114).

Pile heads shall be cut to the levels shown on the Drawings and the cut shall be level,

smooth and horizontal.

No pile boring shall take place within 48 hours of the concreting of any pile which is

within a radius of 10 ft.

Drilling of holes shall be done by straight or reverse rotary rig or any other suitable

method.

After completion of drilling operations the borehole length shall be checked andrecorded.


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The contractor may use Bentonite Slurry for stabilizing the hole.

A manufacturers certificate showing the properties of the bentonite powder must

be submitted by the Contractor.

Concrete shall be placed within thirty minutes after it has been mixed.

The concrete temperature should be maintained within 900F (320C) and

410F (50C).

Pouring of concrete shall be done by efficient tremie technique.

The rate of placing concrete in the bentonite stabilized Hole shall not be less than 30

ft. per hour or more than 50 ft. per hour.

The discharge end of the tremie shall be kept submerged continuously in the

concrete and it shall be kept full of concrete to a point well above the water surface.

The tremine shall not be moved horizontally during a placing operation.

Anchorage arrangements for lowering of re-steel cage and tremmie shall be

sufficiently strong to avert slipping down/free fall of cage or tremmie pipe.

The contractor shall not be permitted to place concrete while it is raining. Should it

rain while the concrete placement is already in progress, the contractor shall carry

on, with proper and sufficient precautions, the concrete placement operations until

the pile is completed. The contractor shall cover the already placed concrete, while

under settling conditions with polythene or similar impervious sheets.

The Engineer must maintain an independent record of Pile Construction as per FR-

11in addition to the submissions by the Contractor.

1.4.5 Safety

The Contractor should monitor compliance of the works with requirements of the Law of

Pakistan for safety, health and environment impact, in the domain of the construction



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CKL 1.4 CHECKLIST FOR BORED CAST-IN-SITU R.C.C. PILES

Sr.

No.Issues Action by

Record/Reporting

Document

1. Location and rating of SOP or CanalBench Marks. Confirm handing over by

the client.


2. Receive request for Survey check by theContractor.

Lab TechnicianContractors

Format3. Contractors Method Statement ofConstruction of Piles. Study, Analyse and

approve.

4. Levels of TBM established by theContractor. Confirm by Joint Survey.

A.R.E./Site

Inspector

Contractors

Surveyor

FR-02

for comments

5. Location of Piles as per approveddrawings. Check by Survey Control and

Dimensional Inspection.

6. Excavated ground Elevations for eachpile location by checking of the survey

data and make record entries by joint

survey.

7. Deployment of proper equipment asdescribed in the Work Methodology

submitted by the Contractor. Discuss

with Contractor and Ensure.Lab Technician FR-02for comments8. Ensure presence of Contractors

qualified experienced and competent

persons to conduct and supervise,

drilling and pile construction.

9. Check by physical Inspection and TestProcedures, all materials to be used in

piling work.

Lab Technician. Ref. Concretework Section 4

Item 1.3.

10. Check by physical Inspection and TestProcedure. The execution of drilling of

pile bore.


11. Receive concrete Pour Authorization.Check all items and approve.


12. The execution of concreting of pile.Check by physical Inspection and Test

Procedures.


LR-07

13. Update Periodically records of all Tests

made during time period.

Lab Technician. FR-10

LR-07

All actions should be taken in accordance with Contract Specifications and Contractors Work

Methodology as approved by the Engineer.


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1.5 PILE LOAD TEST

1.5.1 Objective


procedures and other relevant information to the field staff of the consultants, for their

guidance in performing Quality Assurance of Pile Load Tests, being executed by the

Contractor.

1.5.2 Applicability

This Section covers the Pile Load Test on single vertical Piles for the design confirmation

and for the Proof Load Tests for Quality Assurance of working Piles.

1.5.3 Apparatus for Applying Loads

The apparatus for applying compressive Loads to the Test Pile shall be

constructed so that the Loads are applied to the central longitudinal axis of the

Pile, with minimum possible eccentric loading.

A steel Test Plate of at least 2 in. (50 mm) thickness shall be centred on the

Pile and set perpendicular to the longitudinal axis of the Pile.

The size of Test Plate shall not be less than size of the Pile.

The Test Plate shall be set in high-strength quick-setting grout. The hydraulic jack shall be centred on the Test Plate with a steel Bearing

Plate of adequate thickness between the top of the jack ram and the bottom of

the Test Beam.

The complete jacking system including the hydraulic jack, hydraulic pump and

pressure gauge shall be calibrated as a unit before each test to an accuracy of

not less than 5% of the applied Load.

The hydraulic jack shall be calibrated over its complete range of ram travel for

increasing or decreasing applied loads.

If it is not feasible to calibrate the complete jacking system as a unit, the

pressure gauge may be calibrated independently in which case the jack piston

should be measured to verify the area.

If the hydraulic jack pump is to be left unattended at any time during the test, it

shall be equipped with an automatic regulator to hold the Load constant as pile

settlement occurs.


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Calibration report shall be furnished by the contractor for all testing equipment

for which calibration is required which shall also show the temperature at

which the calibration was done.

1.5.4 Apparatus for Measuring Movements

All reference beams shall be independently supported with supports embedded

in the ground at a clear distance of not less than 8.0 ft. from the Test Pile.

If steel reference beams are used, one end of each beam shall be free to move

horizontally as the beam length changes with temperature variations.

Dial gauges shall have at least a 2-in (50 mm) travel.

The dial gauges shall have a precision of at least 0.01 in (0.2 mm).

Smooth bearing surfaces such as glass shall be provided for the gauge stems. All the dial gauges, scales and reference points shall be clearly marked with a

reference number or letter to assist in recording data accurately.

1.5.5 Load Application by Hydraulic Jack acting against a Weighed Platform

Schematic setup for applying loads to Pile using Hydraulic Jack acting against

weighted Platform is shown in Fig. 1.6.

Centre over the Test Pile a Test Beam of sufficient size and strength to avoid

excessive deflection under Load. The clearance between the top of the Test Pile

and the bottom of the beam after deflection should be enough to accommodate

the necessary bearing plates and hydraulic jack.

Centre a Platform on the Test Beam with the edges of the Platform parallel to

the Test Beam supported by cribbing as far from the Test Pile as practicable but

in no case less than a clear distance of 5.0 ft.

Load the Platform with any suitable material such as soil with a total weight of

at least 10% greater than the anticipated maximum Test Load.

1.5.6 Test Loads

The Test Pile for Pile Load Test for confirmation of Pile design shall be loaded

up to 300%(or a max. of 200 Tons) of the Design Load or failure whichever

occurs first.

Cyclic loading sequence shall be used.

The Test Pile for Proof Load Test shall be loaded up to 150% of the Design

Load, by Standard Loading Sequence.


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1.5.7 Standard Loading Sequence

Apply the Load in Increments of 25% of the Test Load (150% of Design Load).

Maintain each Load Increment until the settlement is not greater than 0.01 in

(0.25mm) per hour but not more then 2.0 hours.

After application of the total Test Load, if the Pile has not failed and the

settlement is not greater than 0.01 in (0.25 mm) per hour maintain the Load for

12.0 hours otherwise allow the Total Load to remain on the Pile for 24 hours.

After the required holding time, remove the Test Load in decrements of 25% of

the Total Test Load with 1.0 hour between the decrements.

If the Pile failure occurs continue jacking the Pile until the settlement equals

15% of the Pile diameter.

Pile is considered to have failed if settlement is more than 0.5 in(12.7mm).

1.5.8 Cyclic Loading Sequence

1stCycle

Loading ( up to 100% of Design Load):

Load Increments of 25% of Design Load (i.e. 0%, 25%, 50%, 75% and 100%).

Each Load Increment to be maintained till the settlement rate is not more than

0.25 mm/hour or for a maximum of 2.0 hours.

Maintain 100% Load for one hour before unloading.

Unloading:

Unload with decrements of 25% of design Load (i.e. 100%, 75%, 50%, 25% and

0%).

Maintain each step for 20 minutes.

2ndCycle

Loading:

1stStage (up to 100 % of Design Load)

Up to 100% design Load use three steps 0%, 50% and 100%.

Each step to be maintained for 20 minutes.

2ndStage (From 100% to 300% or a max. of 200 Tons)

Load increments of 25% each (i.e. 100%, 125%, 150%, 175%, 200%, 225%,

250%, 275% and 300% or a max. of 200 Tons).

Each Load increment to be maintained till settlement rate is not more than 0.25

mm/hour or for a maximum of 2 hours.


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Maintain 300% (or a max. of 200 Tons) Load for 12 hours if settlement is not

more than 0.25 mm per hour otherwise for 24 hours.

Unloading:

Unload in 25% of design Load decrements (i.e.300%, 275%, 250%, 225%,

200%, 175%, 150%, 125%, 100%, 75%, 50%, 25% and 0%).

Maintain each step for one hour.

If the Pile fails, continue jacking the Pile till the settlement equals 15% of Pile dia.

Pile is considered to have failed if settlement is more than 0.5 in. (12.7 mm).

1.5.9 Safety

The Contractor is to ensure compliance with requirements of the Law of Pakistan

for safety, Health and Environment Impact, in the domain of the construction



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CKL 1.5 CHECKLIST FOR PILE LOAD TEST

Sr.

No.Issues Action by

Record/Reporting

Document

1. Details regarding Type of Load Test andLoading Sequence

Geotech Engr./

Cont. site engineer

Letter/

Memorandum

2. The location of the Load Test Pile oridentification of Proof Load Test Pile.

Check by Visual Inspection and Survey

Control.

Geotech Engr./

Cont. site engineer

FR-02

3. Study and Analyse, contractors MethodStatement for Pile Test.

Geotech Engr./

Cont. site engineer

ContractorsFormat

4. Check by Physical Inspection and Test

Procedures, construction of the Test Pilefor Load Test.

A.R.E./Geotech

Engr Cont. siteengineer

Ref. Section-5

LR-07FR-11


Procedure. All Materials, Equipment and

arrangements for Loading Specification.

Cont. site engineer FR-02

6. Monitor/Inspect all stages of loading andunloading of Test Pile and keep

independent records.


7. Submit Pile Load Test Record andReport.

Contractor Contractors

Format

8. Submit Pile Load Test Report toGeotech/Material Engineer.

Lab Technician ContractorsFormat & Letter

9. Recommendations for further PilingWork.

Geotech Engr. Letter/

Memorandum

10. Recommendations A.R.E. FR-02or through

a letter

All actions should be taken in accordance with Part Two, Contract Specifications and

Contractors work methodology as approved by the Engineer.


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1.6 STONE PITCHING & STONE APRON

1.6.1 Objective

Objective of this Section is to provide the scope of applicability of the recommended

guidelines, sequential inspection procedures and other relevant information to the

Contractors field staff , for their guidance in performing quality assurance of stone

pitching and stone apron to the Permanent Work, being executed by the Contractor.

1.6.2 Applicability

This Section covers the placing of stone pitching and stone apron at the specified

locations as shown on the drawings. The recommended guidelines can also be used

for similar works elsewhere in the project, as directed by the Engineer.


The equipment specified in the contract Specifications are only to provide guideline

to assist the Contractor in the selection of proper equipment. The Resident Engineer

must leave the final selection to the contractor. The Contractor may deploy the

following equipment.

Excavators

Dozer and Rippers

Front End Loaders

Dump Trucks

Water Bowser

Dewatering arrangements

1.6.4 Inspection

For Quality Assurance (QA) of Construction activities the Contractors Staff

shall proceed in accordance with CKL-1.6 Checklist for Stone Pitching &

Stone Apron.

Base Filter Layer under Stone Pitching shall consist of well graded material

as specified in BOQ and shown on the Drawings.

The Stones individually shall weigh between 40-120 lbs with 80% shall be

80 lbs or larger and not more than 5% shall weigh less than 40 lbs.


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All interstices in Stone Pitching/Apron shall be well filled with rock Spalls.

The rock Spall shall be rock fragments size between 2 inches and 4 inches.

The surface over which the base filter is to be placed shall be trimmed to the

proper lines and grades and shall be moistened with water and tamped or

rolled with suitable tools or equipment for the purpose of forming a firm

foundation. Wherever over-excavation occurs it shall be backfilled with

specially compacted fill.

The base filter layer shall be placed to a uniform thickness and finished to

reasonably smooth and even surface.

Stone used in the Stone Pitching/Apron shall be clean rough quarry stone

and shall be essentially free from dust, clay, vegetative matter and other

deleterious materials. The stone shall be hard, tough, durable, dense,

resistant to the action of water and air, and suitable in all respects for the

purpose intended. The stones shall be hand packed and placed and bedded

in such a manner that the completed stone pitching is stable and without

tendency to slide.

Construction of stone pitching shall commence at the lowest part of each

structure or section of a structure or canal and continue progressively

upward. The stones, largest of which shall be used at the bottob, shall be wellbedded on a layer of graded Graded Granular Material. In general the size of

the stone used shall have its major dimension the depth of the specified

pitching.

Large open spaces between the stone shall be avoided.

Stone shall be placed so as not to project above neat lines shown on the

drawings.

1.6.5 Quality of Stone

While performing control over procurement and placement of stone and filter

material, the following characteristics of stone and filter material from the

specifications must be observed.

Stone for pitching/Apron should be dense, sound, angular and resistant to

abrasion.


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The loss in Los Angles Abrasion Test for large size Aggregates

(ASTM-C535-96) should not exceed 10% by weight at 200 revolutions or

40% by weight at 1000 revolutions.

The loss in Los Angles Test for small size Aggregates (ASTM-C131-96)

should not exceed 10% by weight at 100 revolutions or 40% by weight at

500 revolutions.

The Specific Gravity of stone (Saturated Surface Dry basis) shall be more

than 2.60.

1.6.6 Test Procedures Frequency and Facilities

The recommended test procedures their frequency and required facilities for an

effective quality control of stone pitching and stone apron are presented in

QAP/Stone/Test Procedures.

1.6.7 Safety

The Resident Engineer must from time to time check the listed item in CKL-5.1

Safety.


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CKL 1.6 CHECKLIST FOR STONE PITCHING AND STONE APRON

Sr.

No. Issue Action byRecord/Reporting

Document

1. Study and Analyse Contractors MethodStatement.

-A. R.E. Rep.

- ContractorsSurveyor

FR-02

2. Confirm by Survey Control Levels of

TBMs established by the Contractor.

3. Check by Survey Control and

Dimensional Inspection Complete

setting out/layout as per drawings and

specifications.

4. Check by visual Inspection and Survey

Control location and level of level pegs.

These should be clear of working area.

FR-02 for comments


Procedures. The Quality of Base Filter

Material, Pitching/Apron Stone and

Rock Spalls.

Cont. site engineer Test Results on

External Lab. Format

or Field Lab.

6. The material of Base Filter, Stone and

Rock Spall should be obtained from

approved source.

Cont. site engineer FR-02 for comments

7. Ensure by Physical Inspection

Placement of stone pitching and Stone

Apron.


8. Update Periodically Records of all Testsmade during the time period. Cont. site engineer Test Record File

All actions should be taken in accordance with Part Two, Contract Specifications and

Contractors work methodology as approved by the Engineer.


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1.7 BRICKWORK

1.7.1 Objective



guidance in performing Quality Assurance of Brickworks for Structures pertaining to the

Permanent Works, being executed by the Contractor.

1.7.2 Applicability

This Section covers the construction of Brickworks for brick masonry and brick lining for

various Structures, being executed by the Contractor.


The Resident Engineer must leave the selection of construction equipment to the

Contractor.

1.7.4 The Consultants Action

The Consultants field staff will take appropriate action as recommended in the checklist

CKL-1.7 Checklist for Brickwork.

1.7.5 Quality of Bricks

The bricks should be regular, uniform in shape and size.

Bricks over-burnt, under burnt and irregular should not be used.

All bricks in oven-dried condition should not absorb more than one sixth ofits weight when soaked for one hour in water at 70 0 F to 800 F and should

show no efflorescence on subsequent drying.

The average compressive strength of five (5) representative bricks should

not be less than 2,000 lbs/in2when tested in accordance with ASTM.C-67.

Each finished brick should be of standard size (9 x 4.5 x 3) first class and

weigh between seven (7) and nine (9) pounds.

All bricks should have a frog. 0.25deep on upper face.


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Each brick for lining should have standard size (9 x 4.5 x 3) first class.

1.7.6 Mortar Composition

Mortar for all brickwork should have mix ratio as specified in BOQ and sufficient water to

produce the proper consistency.

1.7.7 Mortar Sand

Mortar Sand should be as per specifications of sand for concrete works.

1.7.8 Water

The water used for preparation of mortar should be free from objectionable quantities of

silt, organic matter alkali, salts and other impurities.

1.7.9 Safety

The Resident Engineer should monitor compliance of the contractor with requirements of

the Law of Pakistan for safety, health and environment impact, in the domain of the

construction contract. For safety check proceed in accordance with CKL-5.1 Safety.


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CKL 1.7 CHECKLIST FOR BRICKWORK

Sr.

No.Issues Action by

Record/Reporting

Document

1. Study and Analyse. Contractors Method

Statement.

- A.R.E. Rep.

- ContractorsSurveyor

FR-02

2. Check by Survey Control and Dimensional

Inspection, complete setting out/layout

as per drawings. FR-02 for

comments3. Check by Physical Inspection and Survey

Control, location and level of level pegs.

These should be clear of working area.

4. Physically inspect Sand, Cement and

Bricks and confirm adherence to the

specifications by Test Procedure.

External Lab or

Field Lab Format

and FR-02 for

comments

5. Discuss with and Ensure, deployment of

proper equipment as described in the

Work Methodology submitted by the

Contractor.

A.R.E./Site

Inspector/ Cont.

site engineerFR-02 for

comments6. Check all items as per requirements of

specifications and drawings.

A.R.E./Site

Inspector/ Cont.

site engineer

7. Update Periodically, records of all Tests

made during the period.

A.R.E./Field Lab. Test Record Files

All actions should be taken in accordance with Contract Specifications and Contractors Work

Methodology as approved by the Engineer.


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1.8 R.C.C. PIPES & LAYING

1.8.1 Objective



guidance in performing Quality Assurance of providing and laying R.C.C. Pipes, being

executed by the Contractor.

1.8.2 Applicability

This Section covers the Reinforced Concrete spun pipes and includes all pipe formed

culverts, inlets, conduits, underpasses etc.


The Resident Engineer must leave the selection of equipment to the Contractor.

1.8.4 Inspection

1.8.4.1 Quality of R.C.C. Pipes

Consultants field staff will take appropriate action as recommended in

Checklist CKL-1.8 Checklist for R.C.C. Pipes & Laying.

All materials, methods of manufacture strength requirements for concrete pipes

should conform to the requirements of ASTM C-76. Wall B. Class II.

The inspector must read the relevant sections of ASTM C-76, BS.5911 and

BS.2494 and thoroughly understand the requirements related to the R.C.C Pipes

specified on the Drawings.

The Manufacturers Certificate provided by the contractor should be studied

carefully, to check conformance to the ASTM C-76 requirements.

The joints for concrete pipes, bends and junctions shall be of spigot and socket

type as per clause 17 of BS.5911 and BS.2494.

The supplied R.C.C. Pipes should be inspected carefully and the rejection may be

made on account of any of the following:

Fractures or cracks passing through the shell, except for a single end crack

that does not exceed the depth of the joint.


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Defects that indicate imperfect proportioning, mixing and moulding.

Surface defects indicating honeycombed or open texture.

Damaged ends, where such damage would prevent the making of a

satisfactory joint.

Failure to give a clear ringing sound when tapped with a light hammer.

Exposure of the reinforcement when such exposure indicates that the

reinforcement was misplaced.

1.8.4.2 Excavation and Laying

The excavation for pipeline should follow the lines and grades on the Drawings.

The maximum distance from sides of the trench and the barrel of the pipes

should be as shown on the Drawings.

1.8.4.3 Joints for Reinforced Concrete Pipes & Fittings

Joints for concrete pipes, bends and junctions shall be of the flexible spigot and

socket type as specified in clause 17 of BS 5911 incorporating rubber gasket

complying with BS 2494.

1.8.4.4 Bends in Pipelines

Where it is required to form a bend in a pipeline of more than 11 degrees, either

a precast pipe bend which meets the requirements of ASTM C76 shall be placed

or a manhole be installed to lessen the head loss.

Except where pipes are to be laid in a concrete or gravel bed, pipes including

bends shall be laid in a trench with the trench bed hand-shaped to support the

pipe throughout the length of its barrel. Sockets or collars along the pipeline

shall be accommodated by jointing holes formed in the bottom of the trench.

1.8.5 Safety

The Resident Engineer should monitor compliance of the contractor with requirements of

the Law of Pakistan for safety, health and environment impact, in the domain of the

construction contract. For safety check proceed in accordance with CKL-5.1 Safety.


40/59


CKL 1.8 CHECKLIST FOR R.C.C. PIPES AND LAYING

Sr.

No.Issues Action by

Record/Reporting

Document

1. Submit Method Statement. Cont. site engineer FR-02 forcomments or

through letter

2. Study and Analyse, contractors Source(Manufacturer) approval.

A.R.E./Site

Inspector / Cont.

site engineer

FR-02 and

Contractors

Format

3. Physically inspect the pipes suppliedand check, the Manufacturers Certificate

A.R.E./Site

Inspector/ Cont.

site engineer

FR-02

ManufacturersFormat

4. Check by Physical Inspection and SurveyControl, the line, grade and depth of

excavation etc. for Laying Pipes.

Site Inspector

Survey (Contr.)/

Cont. site engineer

FR-02

5. Physically Inspect, excavation Backfill. A.R.E./SiteInspector

FR-02

6. Update Periodically, records of Tests orManufacturers Certificates during the

period.

A.R.E./Site

Inspector/ Cont.

site engineerRecord Files

All actions should be taken in accordance with Contract Specifications, Contractors Work

Methodology and other Contractors Submittals, as approved by the Engineer.


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1.9 STEEL SHEET PILES

1.9.1 Objective


procedures and other relevant information to the field staff of the contractor, for their

guidance in performing quality assurance of Steel Sheet Piling required for the construction

of canal structures.

1.9.2 Applicability

This Section covers the furnishing, handling, transporting, cutting and driving Steel Sheet

Piles as shown on the drawings or directed by the Engineer in accordance with the Contract

Specifications.

1.9.3 Construction Plant

The Resident Engineer must leave the choice of the construction plant and temporary works

for the sheet piling to the contractor. The pile-driving and extracting equipment may be

either percussive or vibratory type. However, the method and the equipment proposed

should not result in ground resonance which might adversely affect neighbouring existing

structures or work under construction.

1.9.4 Inspection

For Quality Assurance of steel sheet piling construction activities, the

Consultants Supervisory Staff shall proceed in accordance with CKL-1.10

Checklist for Steel Sheet Piles.

Steel Sheet Piles section shall be AU-14 made by ARCELOR or equivalent section

approved by the Engineer.

Steel Sheet Piles shall be capable of being interlocked one with another, to form

a continuous wall or diaphragm.

Polystyrene sheets to be fixed at the top of sheet piles shall conform to ASTM D-

4. 549.


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The Bituminous material for sealing steel sheet piling interlocks shall be

equivalent of the Noahs Pitch as manufactured by the Philip Carey

Manufacturing Company of USA.

Steel Sheet Piles which are of different types, cross-section, weight or lengthshall be stored in separate stacks.

Piles during storage shall be supported clear from the ground on suitable

bearers.

The Piles shall be lifted and transported with adequate supports so that piles

are not distorted or damaged in transit.

The Piles shall be driven to lines, levels and dimensions shown on the Drawings.

The line of piles shall not vary from the true line by more than 2.0 inches.

The inclination of the plane of piles shall not vary from the true inclination by

more than 1 in 100.

The inclination of any pile in that plane shall not vary from the line of greatest

slope in that plane by more than 1 in 200.

The finished level of the tip of any pile shall not vary from the true level by more

than one inch.

The finished level of the bottom of any pile shall not vary from the true level by

more than 1% of the specified length of pile.

Piles shall be prevented from being driven below the true level during the

driving of neighbouring piles.

Pile driving shall not be assisted by jets of water or air directed into the ground

except with the approval of the Engineer.

Until the driving of a pile is completed, the Contractor shall not excavate below

existing ground surface adjacent to the pile unless such excavation is either

approved or ordered by the Engineer.

The Contractor with the approval of the Engineer may excavate a trench in

which the steel sheet piling is subsequently pitched and driven.

If such a trench is allowed to be excavated the void between the piles and

undisturbed ground shall be backfilled with reinforced cement concrete (1:2:4)

immediately after driving of the piles is completed.


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Steel reinforcement to be provided for this concrete shall meet the minimum

steel reinforcement requirements set forth in the ACI code 318-05 or as

directed by the Engineer.

Steel Sheet Piles in the permanent works shall be free from holes, other thanthose specified on the drawing or small holes less than inch diameter and not

more than 8.0 inches from the top of the Piles to assist in pitching the piles prior

to driving.

All welding of piles shall be in accordance with the requirements of B.S. 5135 or

an approved equivalent and splicing piles shall be full strength butt welds.

Steel Sheet Piling against which concrete is to be cast shall be clean and

watertight.

All such steel sheet piling shall be free from loose rust, loose-mill-scale, oil,

grease and earth or any other substance which is likely to prevent bonding

between the concrete and the piles.

The surface of steel piles, which shall not be buried in ground on completion of

work, shall be blast cleaned and painted with black bituminous paint applied in

two coats.

The first coat shall be applied within 2.0 hours of blast cleaning and the second

within 24 hours of application of the first coat.

Concrete capping beam shall be formed of reinforced cement concrete, as

specified and Cast-in-situ.


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CKL 1.9 CHECKLIST FOR STEEL SHEET PILES

Sr.

No.Issues Action by

Record/Reporting

Document

1. Confirm by Survey Control, level ofTBMs established by the Contractor.

-A.R.E. Rep.

- Contractors

Surveyor

Survey & Level

Book andFR-02

2. Check and approve by Survey Control,

NSL by checking of the survey data and

make record entries by Joint Survey.

3. Check by Survey Control andDimensional Inspection, complete

setting out/layout.

4. Check by visual inspection and SurveyControl, location and level of level pegs,

these should be clear of working area.

5. Discuss and Ensure, deployment of

proper Equipment/ Plant for Sheet PileDriving.

A.R.E./ Site

Inspector/ Cont. siteengineer

FR-02

6. Ensure by physical inspection, Size,Section and Quality of Steel Sheet Piles.

A.R.E./ Site

Inspector / Cont.

site engineer

FR-02

7. Check by visual inspection and TestResults. Quality of Bituminous Material

for sealing steel piling interlocks.

A.R.E./ Site

Inspector Ext. Lab.

FR-02 and

Manufacturers

Certificate

8. Study and Comment, contractorsproposal for storing, handling and

transporting piles.

A.R.E./ Site

Inspector / Cont.

site engineer

Contractors Formatand FR-02

9. Study and Comment, contractorsproposal for weld procedures.

A.R.E./ SiteInspector./ Cont. site

engineer

FR-02

10. Update periodically. Piling Record A.R.E./ SiteInspector/ Cont. site

engineer

Contractors Format




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R&U of Sulemanki Barrage Quality Assurance Plan

2.1 TYPES OF MATERIAL TESTS

The Quality Control/Quality Assurance tests are of three type i.e.

Tests to be performed at site

These tests are field specific and include the following:

Field Density Tests for compaction control.

Slump test for concrete.

Casting of concrete cylinders for compressive Strength Tests.

Gradation Analysis of concrete aggregates i.e. sand and coarse aggregates.

Los Angeles Abrasion Test for Stone.

Moisture Content of soil.

Temperature of concrete.

Testing of concrete cylinders is required to be done at the Engineers Field Laboratory. The

testing machine at site should be checked and approved by Geotech/Material Engineer of

the consultants.

Tests to be performed at Contractors Field Laboratory

The tests to be performed at Contractors Field Laboratory include the following:

Soil classification Tests

Compaction Tests

Gradation Analysis of Aggregates as required by R.E.

7 and 28 days compressive Strength Tests on concrete cylinders.

Unit Weight of aggregates.

Fresh Density of concrete.

Absorption and Compressive Strength of bricks.

Specific Gravity and Absorption of coarse and fine aggregates.

Los Angeles Abrasion Test for Coarse Aggregate

Soundness of Aggregate

Test to be performed at external laboratories/ Consultants laboratory


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These tests can only be performed in specified off-site laboratories and include tests on

reinforcing steel, cement, abrasion, petrography, soundness of concrete aggregates, water

stop and any other tests required during any problem or dispute.

2.2 TESTING ARRANGEMENTS/EQUIPMENTS

2.2.1 Testing at Construction Site

The Contractor for an individual contract package shall be responsible for providing the

equipment and carrying out these tests in accordance with the Clause 4.3 under the direct

supervision and guidance of the Consultants supervision staff.

The contractor is required to provide and readily make available at construction site the

following equipment,

Earthwork:

Sand - Cone Density Apparatus, complete with base plate and sand bottle.

Density Core Cutter 4 dia, complete with collar and hammer.

Speedy Moisture Tester capacity 20.0 gm. Moisture range 0 20% complete with

electronic balance and plastic carrying case.

Balance Triple Beam 2610 gm capacity with readability of 0.10 gm.

Balance 30 Kgs capacity with readability 1.0 gm.

Drying Oven capacity 108 Litres.

Concrete Work:

Cylinder moulds for concrete 6 dia. Complete with tamping rod (5/8 in dia 20

long) and mallet.

Slump Test Equipment complete with tamping rod 5/8 dia and 24 long.

Curing Tanks These shall be constructed close to the construction site for storing

concrete cylinders till their transportation to the Laboratory for testing.

A reliable compression machine approved by the Consultants Material Engineer.

Thermometers to check fresh concrete temperature.

Note:

The Contractor shall ensure that sufficient No. of the above equipment is available at

site to satisfy the testing requirements of the quantum of work.

Computers with printers should be provided in laboratory.

2.2.2 Testing in the Engineers Field Laboratory


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A material testing laboratory established at site should be equipped and adequately

staffed to carry out the field laboratory tests as per requirements defined in Section

2.1.

This Field Laboratory, established by the contractor and supervised by the

Consultants Quality Control / Assurance staff is to carry out the required tests

and maintain a systematic and retrievable record. Test record should be

computerized.

All Quality Control/Quality Assurance tests specified to be performed in the field

laboratory shall be carried at the designated Field Laboratory at site. (Individual

arrangements by the contractors for this category of tests shall not be acceptable.

The Contractors shall be responsible for providing and transporting the test

specimens to the laboratory under the guidance and supervision of the

Consultants Resident Engineer.

The contractors shall bear the cost of these tests as per rate list available at any

Field or external Laboratory specified by the Engineer.

2.2.3 Testing from External Laboratory

The Quality Control/Quality Assurance tests to be carried out from an external laboratory

defined in Section 2.1 are recommended to be carried out at laboratories mentionedbelow or as directed by the Engineer. The cost of transportation and testing charges shall be

the Contractors responsibility.

Specified Laboratory.

Third Party verification


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2.3 TESTING REQUIREMENTS

The test procedures and the test frequencies for the various construction works have been

summarized in the following tables.

Earthworks Table 2.3 (1)

Concrete works Table 2.3 (2)

Brickworks Table 2.3 (3)

Stone Pitching and Stone Apron Table 2.3 (4)

These tables are intended to provide comprehensive guidelines to the supervision staff as

well as Engineers Field Laboratory personnel.


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Laboratory Record/Reporting Documents

3.1 Laboratory Record/Reporting Documents

( Field Laboratory )Document No. Document Description

SOILS

LR-01 Particle Size Analysis of Soil

LR-02 Moisture Content of Soils

LR-03 Liquid Limit, Plastic Limit and Plasticity Index of Soils

LR-04 Specific Gravity of Fine Grained Soil Particles

LR-05 Laboratory Compaction characteristics of soils

CONCRETE

LR-06 Particle Size Distribution of Concrete Aggregates

LR-07 Concrete Compressive Strength

LR-08 Bricks Tests Report

LR-09 Specific Gravity of Coarse Aggregates

LR-10 Specific Gravity of Fine Aggregates

LR-11 Concrete Batching Plant Calibration

LR-12A Concrete Batching/ Pouring Record Summary

LR-12B Concrete Aggregate Moisture Content at Batching Plant

LR-13 Concrete Mix Design

Note:LR = Laboratory Record


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Field Record/Reporting Documents

3.2 Field Record/Reporting Documents (for Field Inspection/Testing)

Document No. Document Description

FR-01 Field Note for Handing over Survey Reference Points/Bench Marks

FR-02 Field Note (General)

FR-03/A Field Density & Degree of Compaction of Non-Cohesive Soils.

FR-03/B Field Density & Degree of Compaction of Cohesive Soils by Sand Cone

Method

FR-03/C Field Density & Degree of Compaction of Cohesive Soils by Core Cutter

Method.

FR-04 Summary of Compaction Control Tests for Cohesive soils

FR-05 Summary of Compaction Control Tests for Cohesion less soils

FR-06 Format for Bar Bending Schedule

FR-07 Request for Concrete Pour Authorization

FR-08 Concrete Pour Authorization

FR-09 Concrete Cylinders/Cubes Casting and Delivery Report

FR-10 Summary of Cylinder/Cubes Test Results

FR-11 Bored-Cast-in-Situ Pile Construction Record

Note:FR = Field Record


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4. SAFETY REQUIREMENTS

High Standards of safety for men/women and machine must be observed at all times. The

Contractor shall take reasonable measures to prevent members of the public from entering

areas in which maintenance/construction activities are being carried out by the Contractors

Equipment and personnel.


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CKL 4.1 SAFETY REQUIREMENTS CHECKLIST

Sr.

No.Issues Action

Record/Reporting

Document

1. Presence of underground utilities Visual Inspection

FR-02

2. Protective barrier on edge of excavationline and Warning Signs

Visual Inspection

3. Showing where soft materials areencountered, during excavation.

Visual Inspection

4. Employers property is properly protected Visual Inspection

5. - All work areas, walkways, platformetc. are clear of scrap, small tools,

accumulation of mud, grease, oil orslippery substances.

Ensure

6. - All Test Beams, Reaction Frames andPlatform for the pile load tests are

adequately supported at all times.

Ensure

7. - Only authorized personnel arepermitted within the immediate Test

area during Pile Tests.

Ensure

8. - All Reaction Loads are stable andbalanced, during pile load tests.

Ensure

9. - The Equipment in use by contractor isin compliance with HSE regulations.

Ensure


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5. STANDARDS & PROCEDURES

A list of ASTM and British Standards and Procedures, applicable to types of construction

works involved inR&U of Sulemanki Barrage project are presented in the following tables:

Table-5.1

Table-5.2

A copy of all these ASTM and British Standards can be made available to the Site Staff as and

when required.

LIST OF ASTM STANDARDS & PROCEDURES

Sr.

No.ASTM Designation Title

Page

No.

PART 1

A FERROUS METALS

1 A 29/A 29 M-99Std. Spec. for Steel Bars, Carbon & Alloy, Hot-Wrought &

Finished, General Requirements for1

2 A 53-98Std. Spec. for Pipe steel, Black & Hot Dipped, Zinc-Coated,

Welded and Seamless

23

3 A 416/A 416M-99Sts. Spec. for Steel Strand, Un-Coated Seven-Wire for Pre-

Stressed Concrete44

4 A 421/A 421M-98aStd. Spec. for Uncoated Stress-Relieved steel Wire for Pre-

Stressed Concrete49

5 A 501-98Std. Spec. for Hot-Formed Welded & Seamless Carbon

Steel Structure Tubing52

6 A 615/A 615M-96aStd. Spec. for Deformed & Plain Billet Steel for Concrete

Reinforcement58

7 A 980-97Std. Spec. for Steel, Sheet, Carbon, Ultra High Strength

Cold Rolled63

8 A 981-97

Std. Test Method for Evaluating Bond Strength for

15.2mm (0.6") Diameter Pre-Stressing Steel Strand Grade

270, Uncoated, Used in Pre-Stressed Ground Anchors.

65


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Sr.


Page

No.

PART 2

C CEMENTATIONS, CERAMIC, CONCRETE & MASONRY MATERIALS

9 C 29/C 29M-97Std. Test Method for Bulk Density (Unit Weight) & Voids

in Aggregates68

10 C 31/C 31M-98Std. Practice for Making and Curing Concrete Test

Specimens in the Field72

11 C 33-99 Std. Spec. for Concrete Aggregates 77

12 C 39-96Test Method for Compressive Strength of Cylindrical

Concrete Specimens85

13 C 40-99Test Method for Organic Impurities Test in Fine

Aggregates for Concrete90

14 C 42/C 42M-03Std. Test Method for Obtaining and Testing Drilled Cores

and Sawed Beams of Concrete92

15 C 67-02CStd. Test Methods for Sampling & Testing Brick and

Structural Clay Tile97

16 C 76-98aStd. Spec. for Reinforced Concrete Culvert, Storm Drain

and Sewer Pipe109

17 C 78-94Std. Test Method for Flexural Strength of Concrete (Using

Simple Beam with Third-Point Loading)120

18 C 88-99aTest Method for Soundness of Aggregates by Use of

Sodium Sulphate or Magnesium Sulphate123

19 C 97-96Std. Test Method for Absorption and Bulk Specific Gravity

of Dimension Stone128

20 C 109/C 109M-02 Std. Test Method for Compressive Strength of HydraulicCement Mortars (Using 2-in/50-mm Cube Specimens)

130

21 C 117-95Std. Test Method for Materials Finer than 75-m

(No. 200) Sieve in Mineral Aggregates by Washing136

22 C 123-98 Std. Test Method for Light Weight Particles in Aggregate 140

23 C 127-01Std. Test Method for Density, Relative Density (Specific

Gravity), And Absorption of (Coarse Aggregate)143

24 C 128-01

Std. Test Method for Density, Relative Density (Specific

Gravity) and Absorption of Fine Aggregate 149


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Sr.


Page

No.

25 C 131-03

Std. Test Method for Resistance to Degradation of Small-

Size Coarse Aggregates by the Abrasion and Impact in the

Los Angeles Machine

155

26 C 136-01Std. Test Method for Sieve Analysis of Fine and Coarse

Aggregates159

27 C-138/C 138M-01aStd. Test Method for Density(Unit Weight), Yield, and Air

Content (Gravimetric) of Concrete.164

28 C 142-97Std. Test Method for Clay Lumps and Friable Particles in

Aggregates168

29 C 143/C 43M-98 Std. Test Method for Slump of Hydraulic Cement Concrete 170

30 C 144-93 Std. Spec. for Aggregate for Masonry Mortar 173

31 C 150-98 Std. Spec. for Portland Cement 175

32 C 171-97a Std. Spec. for Sheet Materials for Curing Concrete 180

33 C - 172 - 99 Std. Practice for Sampling Freshly Mixed Concrete. 182

34 C 191-01a Std. Test Method for Time of Setting of Hydraulic Cementby Vicat Meedle

185

35 C - 227 - 97aStd. Test Method for Potential Alkali Reactivity of

Cement-Aggregate Combinations (Mortar-Bar Method).191

36 C 231-97Std. Test Method for Air Content of Freshly Mixed

Concrete by the Pressure Method195

37 C 260-01 Std. Spec. for Air Entraining Admixtures for Concrete 203

38 C - 289 - 02

Std. Test Method for Potential Alkali -Silica Reactivity of

Aggregates (Chemical Method). 206

39 C 295-03Std. Guide for Petrographic Examination of Aggregates for

Concrete213

40 C - 309 - 98aStd. Specification for Liquid Membrane-Forming

Compounds for Curing Concrete.221

41 C 494/C 494M-99a Spec. for Chemical Admixtures for Concrete 224

42 C - 535 - 03

Std. Test Method for Resistance to Degradation of Large-

Size Coarse Aggregate by Abrasion and Impact in the Los

Angeles Machine.

233


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Sr.


Page

No.

43 C 566-97 Std. Test Method for Total Evaporable Moisture Contentof Aggregate by Drying

236

44 C 597-83 Std. Test Method for Pulse Velocity Through Concrete 239

45 C 881-99Std. Spec. for Epoxy-Resin Base Bonding Systems for

Concrete242

46 C 920-02 Std. Spec. for Elastomeric Joint Sealants 247


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Sr.

No. ASTM Designation Title

Page

No.

PART 3

D MISCELLANEOUS MATERIALS

47D 422-63 (Re-

approved 1998)Std. Test Method for Particles Size Analysis of Soils 250

48 D 427-98Std. Test Method for Shrinkage Factors of Soils by

the Mercury Method258

49 D - 572 - 88Std. Test Method for Rubber Deterioration by Heat

and Oxygen.

262

50 D 698-00a

Std. Test Methods for Lab Compaction

Characteristics of Soil Using Std. Effort (12,400 ft-

lbf/ft3[600 KN-m/m3])

265

51 D 854-02Std. Test Method for Specific Gravity of Soil Solids by

Water Pycnometer276

52D 1143-81 (Re-

approved 1994)

Std. Test Method for Piles Under Static Axial

Compressive Load283

53 D 1556-00Std. Test Method for Density and Unit Weight of Soil

in Place b