Quality Assurance for MS Pipe
June 2, 2016 | Author: Ram Narendra Nath | Category: N/A
Short Description
Download Quality Assurance for MS Pipe...
Description
Quality Assurance Plan for xxxxxxxxxxxxxxx
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NAME OF WORK
Sr. Proposed Procedure No. No. 1 2 3 4
Description
Remarks
COMPANY/CLIENT/01 Fabrication & Inspection of pipes at shop COMPANY /CLIENT/02 COMPANY /CLIENT/03 COMPANY /CLIENT/04
Cement mortar External Guniting at shop Welding procedure qualification Final Documents for Delivery of pipe
5
COMPANY/CLIENT/05 Trenching
6
COMPANY/CLIENT/06 Pipe laying
7
COMPANY/CLIENT/07 In-situ Lining at Site
8
COMPANY/CLIENT/08 Backfilling
9
COMPANY/CLIENT/09 Shuttering work
10
COMPANY/CLIENT/10 Reinforcement work
11
COMPANY/CLIENT/11 Concreting
12
COMPANY/CLIENT/12 Shotcreting
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Page 2 of 54
NAME OF WORK
PROPOSED PROCEDURE NO.: COMPANY/CLIENT/01 Fabrication & Inspection of pipes at shop 1. Scope: This procedure covers a complete method of manufacturing of MS pipes at Fabrication yard for NAME OF WORK for CLIENT. This procedure also provides a guideline for inspection at various stages during manufacture as well as final inspection before dispatch. 2. Reference: CLIENT and IS 3589: 2001specifications. 3. Material: Hot Rolled Carbon steel plate used for SAW welded pipe shall conforming to IS 2062 / GR B. 4. Method: 4.1 The pipes shall be manufactured as per IS 3589: 2001. 4.2 Before the commencement of fabrication work the manufacturer’s test certificates and heat nos. for plates shall be verified. 4.3 Receipt documents of the plates shall be thoroughly checked. A visual inspection shall be carried out for plate thickness, width, surface irregularities etc. All pipe material shall be from SAIL, TISCO, ESSAR, JINDAL, ISPAT Industries or EQUIVALENT and shall have original test certificate from the manufacturer. 4.4 For smooth manufacturing of pipe and to carry out necessary tests, manufacturer’s shop shall be equipped with the followings: 4.4.1 All necessary equipments to carry out mechanical tests of plates and weld metals. 4.4.2 Hydrostatic testing machines to carry out tests as per relevant IS codes. 4.4.3 Traveling gantry / cranes of capacity 5 tones or above with lifting arrangements. 4.4.4. Mobile cranes for loading / unloading of plates, pipes etc. 4.4.5. Lathe for machining purpose. 4.4.6. Chemical tests, if any, shall be carried out at Metallurgical Laboratory in Bangalore. 4.4.7 Any other equipment required for manufacture / testing of material and pipes even though not mentioned here. 4.5. The factory shall have adequate area and shall also have stacking yard for the stacking of plates, fabricated pipes, scraps etc.
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Page 3 of 54
NAME OF WORK
4.6 The hot rolled carbon steel plates shall be cut, trimmed on both sides for cutting of mill edges and to have constant width. The trimmed plate edges shall be beveled by grinding tools, if calls for and cleaned on both sides by brushes for achieving good welding. The plates shall be formed into a pipe of high dimensional accuracy in the pipe forming device by three rolled bending machine. 4.7 Thickness checking shall be carried out by D Meter / Micro Meter / Vernier califer 4.8 Welding: 4.8.1 Pipes shall be welded by automatic submerged arc welding process as per the requirement of IS 4353. 4.8.2 Before start of welding we shall submit a welding procedure. A sample test piece using the same procedure shall be prepared and tested as per the requirement of IS 7307 / ASME Section IX. The values obtained by successful tests shall be maintained throughout the job. A welding operator shall be qualified using the same parameters. The operators shall be given a proper identity. 4.8.3 The plate edges running together along with the formed pipe shall welded inside at the lowest point by SAW. This shall be followed by outside SAW welding. The welding process shall be fully automatic. Reinforcement of inside welding shall not exceed 1.5 mm thickness. 4.8.4 Manual welding, CO2 welding shall not be permitted except for sealing runs and other minor repair work. 4.8.5 Before engaging any welder for welding, the manufacture shall carry out welder’s qualification test as per IS 7310 / ASME IV. Qualified welder shall be given a proper identity. Any welder found inefficient shall be rejected. 4.8.6 The consumables used for shop welding shall conform to IS 814. 4.8.7 Use of electrodes / filler wires / flux of approved vendors like Advani –Oerlicon / Essab /Anand Electrodes etc. All necessary test certificates shall be provided to meet the requirements of ASME Section II pat C or relevant the Indian Standards. 4.8.8 Manufacturer shall provide adequate equipments and ovens to keep the electrodes / welding consumables in desired temperature and dry. 4.9. Visual Inspection: 4.9.1 After the completion of welding a thorough visual inspection shall be carried out to ensure that the pipe surface and the welding are clean and free from any such defects which can be detected by visual inspection. 4.9.2 Grinding shall be permitted to eliminate surface marks and imperfections like scalbs, seams, tears, laps, silvers etc., provided that after dressing the wall thickness does not fall below specified thickness.
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Page 4 of 54
NAME OF WORK
4.11 Checks prior to Hydro test: 4.11.1 We shall check the pipeline as per the specification prior to hydro test as per the client specification. 4.11.2 Length of pipe and tolerance on that shall be as per IS : 3589 (2001) & CLIENT Specification
_____________________ Prepared by Sr. Engr. Q.C.
_____________________________________ Approved by Head QA / QC & Welding Tech.
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Page 5 of 54
NAME OF WORK
COMPANY NAME Quality Assurance Plan Client
CLIENT NAME
Manufacturer Pipe Size
COMPANY NAME
Thickness
Range 6mm to 20mm
SI
Manufacturing Stage
1
Raw Material
Date : -
Project :- XXXXXXXXXXXXXXXXXXXXXXXXXXXXX Pipe Length:Control Checks
6 Mts / 12 Mts
Reference Documents
Control Procedure
Manner of Records
Mill Test Certificate
Correlation of Mill TC with Plate
2. Dimensional Checks
IS 2062 Gr A / B
3. Chemical Properties 4. Physical Properties
(FE - 410 WA) or Equivalent
As per specification Thk check-'D' Metre / Micro Meter / Vernier Califer
Mill Test Certificate + Lab Test Certificate
1. Marking on Plates
COMPANY Scope
CLIENT/ TPI Scope
Dimensions Check
Review
Perform
5.No Negative Tolerance 2
Welding Procedure
3
Plate Cutting
WPS/ PQR/ WPO
ASME Section IX
ASME Section IX / Indian Standard record of welding procedure
Length, Width, Thick Diagonal Bevel, Root Face
Work Instruction
Measurement with tape, Bevel
WPS/ PQR/ WPO format
Perform
Review
Register
Random
Review
Followed
& Bevelling
Protractor, Micrometer Vernier Caliper
4
Prepinching & Rolling
5
Setup
6
SAW /SMAW
7
Gauging & Straitening
Circularity Check
Work Instruction
Check with revelant template
Random
Review
Root Gap, Edge Allignment
Work Instruction
Mis- Alignment, Visual Inspection
100%
Random
WPS / PQR Based on CLIENT Specification & relevant IS Codes
Current , Voltage, Trolley Speed , Filler Size, Batch no, Flux Batch Make, Visual Inspection for Pinhole, Burn through, Under Cut etc
Register
100%
Random
Outside Dia ,
IS - 3589- 2001
+/- 0.75% of OD
Log BooK
100%
Random
Ovality, Straightness
IS - 3589- 2001 IS - 3589- 2001
+/- 1% of OD 0.2% of Total Length
Welding Parameter Weld Inspection
Name of Company Methodology & Quality Assurance Plan
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Page 6 of 54
NAME OF WORK
8
Leakage Test
Hydrostatic Testing
IS - 3589- 2001
As per Specification
Log BooK
100%
Review / Random
9
Product Analysis
Parent Tensile Guided Bend Test
IS - 3589- 2001
as per IS 4711
Test Reports
As per IS 4711
Review / Random
10
Dimensional Check
Outside Dia Ovality Straightness Length Thickness
IS - 3589- 2001 IS - 3589- 2001 IS - 3589- 2001 IS - 3589- 2001 IS - 3589- 2001*
as per IS - 3589- 2001
Work Inspection Reports
100%
Review / Random
Bevel Angle
IS - 3589- 2001
as per WPS
Works Test
IS - 3589- 2001
Mention of all Test Details
WTC Format
100%
Release Note
11
Certification
Certificate Note :
Raw Material Source
Prepared by Engg. QC (COMPANY)
as per IS - 3589- 2001 as per IS - 3589- 2001 as per IS - 3589- 2001
(Physical, chemical, Hydro etc) M/s Steel Authority of India Ltd / M/s Essar / TISCO / Jindal
Approved by (CLIENT NAME) / (Consultant )
Approved by Manager QC & QA (COMPANY)
Name of Company Methodology & Quality Assurance Plan
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Page 7 of 54
NAME OF WORK
COMPANY NAME CEMENT MORTAR EXTERNAL GUNITING AT FABRICATION YARD PROPOSED PROCEDURE NO.: COMPANY/CLIENT/02 Client : XXXXXXXXXXXXXXXXX 1.0 Scope: This procedure covers a method of External Guniting of pipes with Cement mortar for XXXXXXXXXXXXXXXX. 2.0 Reference: Contract Document & IS 1916 3.0 Material: 3.1 Cement used for External Guniting is ordinary Portland and shall conform to IS 8112. 3.2 Aggregate shall conform to IS 383. 3.3 Water used for preparation of concrete mix shall conform to the requirement of water mixing of IS 456 4.0 Method: 4.1 After hydro testing and dewatering the inside of the pipe shall be thoroughly cleaned. 4.2 The pipe surface shall be cleaned by hand or by sand steel grit blasting if required. After cleaning the external surface of pipe shall be given a coat of cement wash. 4.3 The reinforcement shall be comprise of 50x50x3mm wire mesh conforming to IS: 1566 and 8mm dia. Bar to IS: 1786. The mesh shall be over lap each other by a minimum of 100mm and be tied with mild steel wire at 200mm intervals. The reinforcement shall be held off the pipe wall by a series of 10 nos equally spaced 8mm dia. Reinforcement bars which will run the full length of the coating. Clear cover shall be provided to the reinforcement. 4.4 Cement mortar shall be composed of cement, sand and water, well mixed to obtain a dense homogeneous Guniting that will adhere firmly to the pipe surface. The proportion of cement and sand shall be 1: 3 by volume. The Cement content shall be 600 Kg/m³ and water : cement ratio by mass shall not exceed 0.3:1 Name of Company Methodology & Quality Assurance Plan
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Page 8 of 54
NAME OF WORK
4.5 The cement Mortar shall be done by spraying method by use of a compressor and nozzle specifically designed. The nozzle shall be held at distance of 65mm to 100mm and position so that the stratum of flowing materials shall impinge as nearly as possible at right angles to the pipe surface. 30mm thick guniting shall be shot in one coat. A length of 150mm at each end of pipe shall be left ungunited to facilitate site welding. The ungunited portion of pipe at each ends shall be coated with M15 concrete by hand after the field welding and hydraulic testing are completed. 4.6 The thickness of the External Guniting shall be as given below : Minimum thickness of External Guniting (mm) 1025 to 3028
(mm) 30
Tolerance in thickness shall be according to code specifications. Strength: The compressive strength of cement mortar shall be 25 N /mm2. 4.6 Curing: After 12 hours or after initial setting of Cement mortar after application of coating, the curing shall be commenced. The coating shall be kept continuously moist by sprinkling water and keeping wet gunny bags and as per IS code and CLIENT specification.
Document: Inspection & Test Plan formats COMPANY/CLIENT/02-01 COMPANY/CLIENT/02-02 COMPANY/CLIENT/02-03
Name of Company Methodology & Quality Assurance Plan
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Page 9 of 54
NAME OF WORK
COMPANY NAME Project:
XXXXXXXXXXXXXXXXXXXXXXXX
Client:
CLIENT NAME
S.NO
1 2
Activity Description Inspection of RAW materials such as cement, sand, water etc. Surface preparation check
3
Pipe Surface cleaning
4
Cube testing
5 6
Guniting thickness check Visual check for smoothness, defects etc.
Verification by COMPANY
Verification by CLIENT
R
R
W
R
W
R
W
RM
W
RM
W
RM
Records to be Submitted Outside Laboratory test report COMPANY/CLIENT/0802 COMPANY/CLIENT/0802 COMPANY/CLIENT/0802 COMPANY/CLIENT/0802 COMPANY/CLIENT/0802
W – Witness RM – Random R – Review Documents
Name of Company Methodology & Quality Assurance Plan
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Page 10 of 54
NAME OF WORK
COMPANY/CLIENT/02-01 COMPANY NAME Project: PROJECT NAME Client:
CLIENT NAME
Report No. Material
SL NO.
Date: Dia/Thickness: PIPE NO. / PIPE ID
SURFACE CLEANING CHECKED
FOR COMPANY NAME
GUNITING THICKNESS CHECKED
VISUAL CHECKED FOR SMOOTHNESS DEFECTS ETC.
REMARKS
FOR CLIENT NAME
Name of Company Methodology & Quality Assurance Plan
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Page 11 of 54
NAME OF WORK
COMPANY/CLIENT/02-02
CUBE TEST REPORT Project:Agency:Client :Cube ID Mark
PROJECT NAME System
COMPANY NAME CLIENT Date of Casting
Location & Detail of Structures
Date of Testing
Age (Day)
Dimension of Cylinder L B H (mm) (mm) (mm)
Area (Sqm)
Wt. Of Cylinder (Kg)
For COMPANY NAME
Density
Compressive Strength (N/Sqmm)
Avg. Compressive Strength (N/Sqmm)
Remarks
For CLIENT NAME
COMPANY/CLIENT/0203
Name of Company Methodology & Quality Assurance Plan
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Page 12 of 54
NAME OF WORK
Quality Assurance Plan for CM External Guniting at Shop
Ref No.
COMPANY NAME Client : M/s CLIENT NAME
Date: CM Guniting:
Project: PROJECT NAME System for CLIENT.
Pipe Size: Sr. No.
Activity
Description
Check Point
Test Frequency
Reference Code / Spec.
Acceptance Criteria
Format/ Record
COMPANY
1
2
3
4
5
6
7
8
9
10
11
Pipe Cleaning
Surface Preparation
Before starting of all the activities inside the pipe
Every Pipe
Raw Material a)Cement (OPC-43 Gr)
Review MTC
Before Application
b) Sand
Sieve Analysis
1
CLIENT
Bid Sp- IS 1477Part -I, Class-B, near white
Bid Spec
Record
100%
100%
R
Each Batch
IS:8112
As per IS:8112, Bid Spec. Clause No.5.3
Record
100%
100%
R
At QA/QC Lab
For each lot
IS.2116 Cause A3.1 of IS;3589
As per IS: 383 Bid. Spec. 5.3
Record
100%
R
R
Requirement as per IS:456
As per IS: 456 Bid. Spec. 5.3
Record
100%
100%
R
Inspection Only
Verification
Record
100%
R/A
R
2
c) Water
Quality of Water
Source of Supply
Once for each source + every three months
d) M.S. Pipe
Diameter
Store/ Stock yard
Every Pipe
Name of Company Methodology & Quality Assurance Plan
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Page 13 of 54
NAME OF WORK
3
Mortar Mix
Nominal Mix
Mix Proportion 1:3 (Cement: Sand)
Per Batch Every two months
Test
Visual
QA / QC Lab
100%
Thickness
QA / QC Lab
Uniform 100% Thickness
Cube Test
At QA / QC Lab
IS:1916
Record
100%
R
R
Record
100%
W
R
Bid Spec Clause 5.6.4.7
Record
100%
R/ W 10%
R
As per IS:1916
Bid Spec Clause 5.6.4.8
Record
100%
W
R
IS: 1916
IS:1916 & Bid Spec 5.6.4.6
Record
100%
R/A
R
Clause A-7-3of IS:3589
4
Curing
QA / QC Lab
Physical check record with time
Bid. Spec. Clause 5.6.4.1, IS:3589 Bid. Spec. Clause 5.6.4.7
LEGEND - R-REVIEW, W-WITNESS, AAUDIT
For SAISUDHIR INFRASTRUCTURES LTD.
For CLIENT NAME
Name of Company Methodology & Quality Assurance Plan
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Page 14 of 54
NAME OF WORK
COMPANY NAME
WELDING PROCEDURE QUALIFICATION PROPOSED PROCEDURE NO.: COMPANY/CLIENT/03 PROPOSED WELDING PROCEDURE FOR SITE BUTT JOINTS IS 7307 Part I Procedure No. COMPANY/CLIENT/06 Weld Preparation for SMAW Process 5 to 15 mm thickness pipe
1st Pass Welding
Run Sequence and completed weld
DOUBLE SIDE FULL PENETRATION ‘V’ GROOVE WELDS
600 + 50 - 00
600 + 50 - 00 Well Sequence 3
T
2 1st pass Final pass from second side
1.5 to 2 mm 1.5 to 3 mm
Back grinding shall be done on the second side
Material IS 2062 grade B / SA 106 Gr. B Welding position – ALL Pre-heating: Ambient Interpass temperature: 200o C
Post-weld heat treatment: N.A.
WELDING CONSUMABLES Filler material Make: Any reputed manufacturer. (AOL / D& H(MEDIO)
Flux: Rutile
Type SFA 5.1 E 6013 Size 2.5 dia 3.15, 4 mm dia current range – as recommended by the manufacturer. -as per IS
Approved by (Head Welding Technology & Q.C.) Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
Page 15 of 54
NAME OF WORK
Contd…2
Type of Test IS 7307 Part I
Procedure No. COMPANY/CLIENT/03 Non-destructive tests Visual Magnetic particle Penetrant : Radiography /Ultrasonic Destructive tests Transverse tensile
Tensile Strength
Yield Stress
Location of fracture
All-weld tensile
Tensile Strength
Yield Stress
0.2 % proof Stress
Elongation
Guided band tests Root
Side
Face
Root
Side
Face
Root
Side
Face
Root
Side
Face
Frequency of Tests as per ASME Sec IX
Fillet weld fracture Macro-examination Hardness survey Additional tests Remarks Inspective authority Witnessed by Date Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
Page 16 of 54
NAME OF WORK
COMPANY NAME
PROPOSED WELDING PROCEDURE FOR SITE BUTT JOINTS IS 7307 Part I
Procedure No. COMPANY/CLIENT/03 Weld Preparation for SMAW Process Run Sequence and completed weld 1st Pass Welding
5 to 15 mm thickness pipe
SIGNGLE SIDE FULL PENETRATION ONE SIDE ‘V’ GROOVE WELDS 600 + 50 - 00
600 + 50 - 00 Well Sequence 4 3 2
T
2nd pass onwards-E 6013
st
1 pass with E6010
1.5 to 2 mm
Pipe shall be fixed at 450 +/- 50
1.5 to 3 mm
Test plate Material SA 106 grade B / IS 2062 Gr. B - 6 inches dia. Schedule 80 Welding position – ALL (6G) Pre-heating: Ambient Interpass temperature: 200o C
Post-weld heat treatment: N.A.
WELDING CONSUMABLES Filler material
Flux: Rout pass Cellulos Further pass by
Rutile Make: Any reputed manufacturer.( AOL / ESSB / ANAND / HONAVAR for E 6013) Root pass welding AOL / ESSAB /LINCOLN FLEET WELD – 5P+ Type SFA 5.1 E6010 for root pass followed by E 6013 Size 2.5 dia 3.15, 4 mm dia current range – as recommended by the manufacturer.
Approved by (Head Welding Technology & Q.C. Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
Page 17 of 54
NAME OF WORK Contd…2
Type of Test
IS 7307 Part I Procedure No. Non-destructive tests Visual Magnetic particle Penetran : Radiography /Ultrasonics Destructive tests Transverse tensile
Tensile Strength
Yield Stress
Location of fracture
All-weld tensile
Tensile Strength
Yield Stress
0.2 % proof stress
Elongation
Guided band tests Root
Side
Face
Root
Side
Face
Root
Side
Face
Root
Side
Face
Frequency of Tests as per ASME Sec IX
Fillet weld fracture Macro-examination Hardness survey Additional tests Remarks Inspective authority Witnessed by Date Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
Page 18 of 54
NAME OF WORK
Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
Page 19 of 54
NAME OF WORK
COMPANY NAME PROPOSED WELDING PROCEDURE IS 7307 Part I Procedure No. COMPANY/CLIENT/03 Weld Preparation for SAW Process TWO PASS SQUARE WELDS Run Sequence and completed weld 1st Pass Welding Figure 1 A – 6 to 10 mm thk
1st PASS
Figure 1 C
FINISH PASS
0 to 1mm
T
Flux Backing First or Backing Pass
2 OR 3 PASS SINGLE ‘V’ GROOVE WELDS
Figure 2 A – 10 to 15 mm thk
Figure 2 B
Figure 2 C
600 + 50
FIRST OR BACKING PASS
2mm
T
T
T
⅓t 0 to 1mm
Flux Backing
FINISHING PASS (CHIP BACK 10 X 3.2 MM GROOVE IF DESIRED)
Cu. Backing / Flux backing shall be provided during first pass welding. Dimensions of test piece: 800 mm x 400 mm x Thickness Parent material: IS 2062 Welding position : 1G Position of test piece: Down Hand Pre-heating: Ambient Post-weld heat treatment: N.A. o Interpass temperature: 200 C WELDING CONSUMABLES Filter material Make : Any reputed manufacture Agglomerated Type : SFA 5.17 EL8 Wire Composition : 5.17 F7 AZ EL8 Size : 3.15 Dia Current Range : 450 Amps – 600 Amps Voltage : 28 - 32 Speed : 450mm – 600mm /minute
Flux Type of flux : Composition of gas : N.A. Flow rate :N.A.
Approved by (Head Welding Technology & Q.C.) Contd…2
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Page 20 of 54
NAME OF WORK
Type of Test IS 7307 Part I
Procedure No. COMPANY/CLIENT/03 Non-destructive tests Visual Magnetic particle Penetrant : Radiography / Ultrasonic Destructive tests Transverse tensile
Tensile Strength
Yield Stress
Location of fracture
All-weld tensile
Tensile Strength
Yield Stress
0.2 % proof stress
Elongation
Guided band tests Root
Side
Face
Root
Side
Face
Root
Side
Face
Root
Side
Face
Frequency of Tests as per ASME Sec IX
Fillet weld fracture Macro-examination Hardness survey Additional tests Remarks Inspective authority Witnessed by Date
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Page 21 of 54
NAME OF WORK
COMPANY NAME
FINAL PIPE DESPATCH FROM SHOP PROPOSED PROCEDURE NO.: COMPANY/CLIENT/04 Project: PROJECT NAME System for CLIENT Client : CLIENT NAME
Pipe dispatched shall have following documents. 1) Final Inspection report ( Format enclosed. ) 2) Raw material mill test certificate. 3) Mortar lining report. 4) Tape Coating Report. 5) Joint Inspection Report ( If Applicable. )
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Page 22 of 54
NAME OF WORK
COMPANY NAME FINAL INSPECTION REPORT PROJECT: PROJECT NAME System CLIENT: INSPECTION:
CLIENT NAME
PIPE SIZE: ______
M/S.
MATERIAL: IS 2062 Gr. B. PIPE INSPECTION
PIPE NO
HEAT NOS.
THICKNESS
TOTAL LENGTH: -
LENGT H
CIRCU M
:-IS -3589 : 2001,FE 410
STRAIGHTNESS
PIPE OVALITY
LS/CS WELDING
Mtrs.
NOTE: All pipes are Hydraulically Tested at _____Kg/Cm2 & Found Withstanding the Pressure Satisfactorily
ENGINEER INCHARGE
FOR COMPANY / QC
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Page 23 of 54
NAME OF WORK
COMPANY/CLIENT/0701
COMPANY NAME
TRENCHING PROPOSED PROCEDURE NO.: COMPANY/CLIENT/05 1.
Scope: This procedure covers the work method for trenching of pipeline works.
2.
Method: After line out the area shall be barricading by suitable means for protection against risk of accident due to open excavation sufficient safety measures such as red light at night will be placed at suitable interval. Excavation adjacent to service line in congested area shall be done manually, otherwise trenching shall be carried out by equipments. Depending upon the depth of excavation and nature of soil the trench shall be shored wherever necessary and kept dry so that the workmen can work therein safety and efficiently. The discharge of the trench dewatering pumps shall be conveyed either to drainage channels or to natural drains and shall not be allowed to spread in the vicinity of the worksite. The width of the trench shall be kept to a minimum consistent with the working space required. Pipe Normal Bore (mm)
Bottom clearance (mm)
Side Clearance (mm)
600 to 1000
250
400
1050 to 3000
300
500
When rock or boulders are encountered, the trench shall be trimmed to a depth of at least 300 mm below the level at which the bottom of the barrel of the pipe is to be laid and filled with non-comprising material like sand to give curved seating. Open cut trench shall be barricaded to protect the life, property or the work. When closed sheeting is required, it shall be so driven as to prevent adjacent soil for entering the trench either below or through.
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Page 24 of 54
NAME OF WORK
While carrying out excavation work the excavated material/earth shall be placed at least 3 meter away from the trench edges or ½ of the trench depth, whichever is more. All excavated material shall be stacked in such a manner that it does not endanger the work and avoids obstructing laying works. Natural water courses shall not be obstructed. During construction work if it is necessary to close the road, suitable signs indicating that a road is closed shall be placed and necessary diversion signs for proper maintenance of traffic shall be provided. Temporary support, adequate protection maintenance of all underground and surface structures, drain, sewers and other obstructions encountered shall be provided. Trees, shrubbery fences and other properties shall be protected unless their removal is shown in the drawing. Where trees have been cut, the tree roots within a distance of half meter from the side of the pipeline shall be removed or killed. A minimum clearance of 150 mm shall be provided between the pipeline and such services. 3.
INSPECTION The alignment of the trench will be checked as per the survey drawing.
4.
BEDDING When rock or boulders are encountered, the trench shall be trimmed to a depth of at least 300 mm below the level at which the bottom of the barrel of the pipe is to be laid and filled with non-comprising material like sand to give curved seating. The class of bed and surround to be used are indicated Below Class of Bed
Description of bedding
Class A
Mass Concrete
Class N
Well Graded
Class S
Granular materials
The concrete to be used for Class A bedding and surrounding shall be M15. Class A bedding shall be used at all road crossings under the road and for a distance of 5M back from the back edge of road or foot path. Concrete shall not be placed until the pipes are jointed, inspected and tested. Before placing concrete the pipes shall be supported near each joint a padding of compressive material on a Pre cast concrete block. The concrete shall be placed to ensure full contact with pipe barrel through out its length. Class N bed materials shall only used where the pipe trench is found hard rock or other wise as directed by the engineer. The graded granular bed materials for use in Class S bedding and surrounding shall consist of durable gravel crushed stone dust or disintegrated rock. All Class S graded materials shall pass through test sieves to IS 460 (part1). The granular materials shall be evenly Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
Page 25 of 54
NAME OF WORK
spread over the full width of trench and lightly compacted to higher than level corresponding to the outer side of the pipe barrel to allow for settlement of the pipe to the correct level.
COMPANY NAME
PIPE LAYING PROPOSED PROCEDURE NO.: COMPANY/CLIENT/06 1. Scope: This Procedure covers the work method for Laying of pipes below ground as well as above ground. 2. Reference: Contract document no. Vol II section IV: Part V of CLIENT NAME and IS 5822:1994 3.Method: Laying of pipes underground: a) Laying shall be started after the trenching is completed as per approved procedure. b) If at site situation requisition necessity sand bedding, the sand bedding of
minimum shall be provided below the pipe, prior to laying the pipe in trenches. Care shall be taken to ensure that the sand used for bedding is free from clay lumps, injurious amounts of dust, organic matter or any other deleterious materials. c) After satisfactory completion of trench bottom, the level shall be checked to get the
required minimum cover of 1.2 meter above the top of the pipe, d) Trench shall be adequately widened at bends before hand to avoid tension in pipe
section while lowering. e) Where water is present in the trench, no laying shall be permitted. The pipe shall be
laid after complete dewatering of the trench. f) Pipes shall be laid in trenched on suitable supports such as sand bags to facilitate
the welding and coating of the field joints. g) Pipe laying shall be carried out with help of shear legs or cranes using belts or
slings covered with suitable non- abrasive material, to ensure that no damage is done to the coating of the pipe. h) At first two pipes shall be laid. After completion of the circumferential welding
further laying operation shall be started. i)
Where the trench is sheeted, the pipe shall be lowered into the trench by removing at a time one or two struts only. Care shall be taken to ensure that no part of the strutting is disturbed or damaged. If necessary additional struts may be fixed during lowering.
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NAME OF WORK
a) Handling of pipes shall be done as per approved procedure. b) At first pipes shall be laid on temporary supports. After laying two pipes the pipe section shall be aligned and only after completion of welding further laying operation shall continue. Simultaneously permanent support of the previous pipe section shall be provided. c) Thrust blocks and anchor blocks shall be provided wherever necessary to prevent unbalanced water pressure and temperature stress. d) For all pipelines laid above ground, provision for expansion and contraction on account of temperature variation should be made by providing between two fixed supports or anchorage. e) Valves, man holes, tees and bends shall be provided in the pipeline as per approved drawing. 2.
Documentation: Site joint report format Daily progress report Manpower deployment status
– – –
COMPANY/CLIENT/11-01 COMPANY/CLIENT/11-02 COMPANY/CLIENT/11-03
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NAME OF WORK
COMPANY NAME PROJECT : PROJECT NAME System Client:
CLIENT NAME
REPORT NO JOB NO:
DATE:
SPREAD: BETWEEN PIPE NO. / PIPE ID
FROM TP NO._______ DIA THK
TO
AND TP NO. ____________
COVER CHECK
PADDING DONE ( IF REQUIRED)
ALIGMEN T CHECK
PROPER SUPPORTING DONE
REMARKS
PROGRESS IN METER PREVIOUS CUMULATIVE
TODAY
FOR COMPANY NAME
FOR CLIENT NAME
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NAME OF WORK Name of the Project : PROJECT NAME System. DAILY PROGRESS REPORT Sr. No.
Activity
Start
Finish
Quantity
Unit
Work done till Target
Actual
Work done on Target
Actual
Date : Cumulative work done Target
COMPANY/CLIENT/11-02 Name of Company Methodology & Quality Assurance Plan
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Page 29 of 54
Actual
Overall Completion
NAME OF WORK Name of the Project : PROJECT NAME System for CLIENT. II
MANPOWER DEPLOYMENT STATUS:
S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13
Category Manson Carpenter Fitter Plumber Operator Painter Electrician Mechanic Welder/Rigger Mate Male Mazdoor Tapker (Stone cutting) Helper TOTAL
Nos
III
PLANT & EQUIPMENTS
IV MATERIAL RECEIPTS
Category
Nos.
Item
Quantity
Remarks
Excavator JCB Excavator POCLAIN Dumper Batching Plant Concrete Mixer Concrete Pump Vibrator Welding Machine De-watering Pumps Cube testing Machine Compressor Rock Splitter Cutting & Bending Machine
REMARKS :
COMPANY/CLIENT/11-03 Name of Company Methodology & Quality Assurance Plan
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NAME OF WORK
COMPANY NAME IN-SITU LINING AT SITE PROPOSED PROCEDURE NO.: COMPANY/CLIENT/07 1.
SCOPE:
This procedure covers an in-situ Cement mortar lining in side the pipe for PROJECT NAME System for CLIENT Reference IS 11906 & CLIENT Specifification MATERIAL a. Ordinary Portland Cement conform to IS- 8112 b. Aggregate conform to IS 11906 Table – 1 c. Water as per requirement of IS 456. METHOD: The inside of the pipe shall be cleaned to remove all rust, chemical or other deposits, loose mill scale and remains of old materials by chemical or mechanical (power Driven cleaner) means to the approval of the Engineer. Immediately prior to the travel of the lining machine through pipe line, all foreign materials to be removed. Cement mortar in the proportion of cement and sand shall be applied 1:1.5 to such a consistency so as to produce a dense and homogeneous lining that will adhere firmly to the pipe surface. The cement mortar mix shall comply with strength and density requirements specified in IS 11906. The lining thickness shall be in 14mm with a negative tolerance of 1mm and with a positive tolerance of 3mm. In-situ Lining method is done in one course by hauling the machine with constant speed through the pipe and the mortar is spinned against the inner pipe surface by an electricdriven, fast-rotating centrifugal discharge head. The rotating trowels mounted on axially aligned arms behind the centrifugal head are pressed with a certain spring tension against the mortar surface granting a smooth finish. The service lines for electricity and mortar are pulled through the pipeline by means of a winch whose speed is adapted to the operating Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
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NAME OF WORK
speed of the lining machine. The otherwise automatic operations performed inside the pipeline are monitored by a machine operator. The electric propelled lining machine mounted on pneumatic tyres passes (at constant speed) through the pipe at (a constant speed). The lining machine is equipped with a funnel-shaped hopper serving as intermediate storage for the cement-mortar pumped through the pumping hose towards the machine. A conveyor screw then forces a constant amount of mortar from the hopper to the centrifugal head (Consequently), the selected traveling speed of the machine determines (in consequence) the thickness of the layer. Steel finishing towels shall be used for hand application except at bends. All hand finishing work in a section of the pipeline shall be completed within 24 hrs after completion of the machine application of mortar lining to that section. After completion of the mortar lining and hand finishing of a section of pipeline curing shall commence immediately. Curing should not later than 8 hrs after mixing of mortar. The lining shall be kept continuously in moist condition for a period as per IS code and as per specification of Employer. Strength: The compressive strength of cement mortar shall be 25 N /mm2 DOCUMENTATION Ref Shop Formats
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NAME OF WORK
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NAME OF WORK
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NAME OF WORK
COMPANY NAME
BACKFILLING PROPOSED PROCEDURE NO.: COMPANY/CLIENT/08 1. Scope This Procedure covers the work method for backfilling of trenches. 3.Method 3.1. On Completion of the pipe laying operation and field welding in any section, for a length of 100 m, backfilling shall be started leaving the filed joints open for hydrotest and coating. 3.2. Special care shall be taken to prevent possible buckling of pipes or any other injuries to the pipe, joints and coating during backfilling operation. The excavated material nearest to the trench shall be used first. 3.3. Backfilling shall be carried out simultaneously on both sides of the pipe, so that unequal pressure does not occur. 3.4. Only soft earth and murrum of good quality free from stones larger than 75 mm in size and free from boulders, root , vegetation etc, shall be utilized for filling in 30 cm all around for pipes less than 1200 mm dia and d/4 for pipes greater than 1200 mm dia. 3.5. The remaining portion of the trench may be filled in with a hard and soft material free from boulders and clods of earth larger than 150 mm in size. Filling shall be done in layers not exceeding 150 mm in thickness accompanied by watering, ramming etc. so as to be compacted to 95 % of the maximum dry density. 3.6. The trench shall be refilled so as to build up the original ground level keeping due allowance for subsequent settlement likely to take place. If required, reusable materials shall be replaced properly backfilling. 4. Inspection Inspection shall be done to ensure proper compaction of the soil as per requirement.
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NAME OF WORK
COMPANY NAME
SHUTTERING WORK PROPOSED PROCEDURE NO.: COMPANY/CLIENT/09 Project :
PROJECT NAME System.
Client:
CLIENT NAME
1. SCOPE This procedure covers erection and removal of form work and checking of form work. 2. METHOD A) FORM WORK MAKING a. Check if the shutters are properly cleaned to remove the concrete/mortar and protruding nails. b. Formwork shall be made to the exact dimensions within the permissible tolerances. c. Required thickness and quality of plywood confirming to IS: 6461 or steel or as directed by CLIENT shall be used to meet the requirement of design and surface finish. d. Erection of form work. e. Erect staging / shuttering as per drawing/sketched in such a way that de-shuttering can be done easily including provision for re-propping, if being planned. f. Check the location, line, level, plumb and dimensions of the form work to ensure that the deviation are within the permissible limits. g. Apply form oil/other coating as released agents before reinforcement steel is placed. h. Check all shutters are properly aligned and fixed. i. Check all the spanning members have proper bearing at the supports. j. Wedges of jacks shall be secured in position after the final check of alignment. k. Forms shall be thoroughly cleaned of all dirt, mortar and other matters such as metals, blocks, saw, dust and foreign materials before concreting if required through clean out opening. l. Check all the gaps / openings are properly closed to avoid leakage. m. Inspection of form before concreting. B) REMOVAL OF FORMS All form shall be removed after the minimum period stipulated below without damage to the concrete including removal without shock. a) Minimum period before removal of form work : Wall, columns and vertical faces of all 24 to 48 hrs (as may be Structural member decided by the Engineer- In-charge) Slab (props left under)
3 days
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NAME OF WORK
Beams soffits ( props left under) Cantilever construction
7 days Formwork shall remain till Structures for counter acting or bearing down have erected and have attend sufficient strength ( 14 days minimum)
Removal of Props under slabs : Spanning up to 4.5 mtr
7 days
Spanning over 4.5 mtr
14 days
Removal pf props under beams : Spanning up to 6 mtr
14 days
Spanning over 6 mtr and up to 9 mtr
21 days
Spanning over 9 mtr
28 days
b) Form work components shall not be dropped but shall be lowered without damage to the components and structure. c) All the removal form work material shall be cleaned immediately and stacked properly for re-use. 3. INSPECTION Alignment of shuttering shall be checked before pouring of concrete (Refer Pour Card) 4. DOCUMENTATION : Form work Check List Format No. COMPANY/CLIENT/13-01
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NAME OF WORK
FORM WORK CHECK LIST Name of the Project : PROJECT NAME System
Client : CLIENT NAME Contractor : M/s COMPANY NAME. Name of the Building : Concrete Element & Loaction :
Inspection Required on: Date: __/__/____ Time: __.__
Approved Drawing No. Y=Yes, N=No and Na= Not Applicable S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Name of Activities
Inspection Required on: Date: __/__/____ Time: __.__ Contractor’s Engineer
ENGINEER. INCHARGE
Formwork design/drawing/sketch approved including deshuttering arrangements. Trial panel approved (if required) Formwork alignment correct Formwork level correct Formwork dimensions correct Formwork member quality acceptable False work member sizes correct Face boarding/plywood/metal thickness correct Joints between panels closed (no.gaps) Joints between panels flush (no steps/lips) Panel flatness acceptable Tie rod material sizes/spacing/material correct Tie rods tight, face cone flush Box outs, cast- in - items, ducts fixed correctly securely Chamfers/fillets sizes, straightness, fixing acceptable Formwork clean Formwork release oil material approved Formwork release oil applied correctly Contraction/expansion joint preparation satisfactory Shutter vibrators (if required) location and fixing arrangement approved.
INSPECTED BY: (Contractor's Engineer)
APPROVED BY: (Engineer - in - Charge)
Name : Sig. & Date
Name : Sig. & Date
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NAME OF WORK
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NAME OF WORK
COMPANY NAME REINFORCEMENT WORK PROPOSED PROCEDURE NO.: COMPANY/CLIENT/10 1.
SCOPE This procedure covers method for cutting, bending and typing of reinforcement and inspection of work.
2.
REFERENCE Contract “Technical Specification”.
3.
METHOD A)
REINFORCEMENT HANDLING : i. ii. iii. iv. v.
B)
Receive reinforcement along with manufacturers test certificate & submit the test certificates to CLIENT. Check the quantity of reinforcement corresponding to weight slip, transport and unload the same at reinforcement yard. Against requirement from site, bars shall be cut and bent to shape and dimension. Reinforcement shall be tied as per the latest AFC drawing and any extra bars provided at site shall be recorded in the pour card. Unusable cut rods and scrap reinforcement shall be properly placed at yard.
BAR BENDING SCHEDULE : i. Prepare bar bending schedule based on the latest AFC drawing and to be submitted to CLIENT for revision. ii. Bar bending schedule shall clearly specify the following a) b) c) d) e)
Material identification Bar dia Number of bars Cut length Shapes
iii. Bar bending schedule shall take into account the following field/design requirement. a) Desirable lap location and staggering of laps b) Lap lengths c) Development length/anchorage length. C)
CUTTING, BENDING AND PLACING
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NAME OF WORK
i. Bar shall be clean, free from rust, mud and oil and shall be used from approved lot. ii. Cutting and bending shall confirm to the details given in the approved bar bending schedule. iii. Place the reinforcement as per AFC drawings ensuring the following aspects property.
D)
4.
Type and size of bar. Number of bars. Location and length of laps, splices. Curtailment of bars. In two way reinforcement, check the direction of reinforcement in various layers. Adequate number of chair, spacer bars and cover blocks. Size of cover blocks. Length and quality of welding, if any.
Reinforcement may be placed within the tolerance whenever required as per Technical Specification. DOCUMENTATION Bar Bending Schedule format No COMPANY/CLIENT/14-01
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NAME OF WORK
COMPANY NAME Name of Project: PROJECT NAME System. Client : CLIENT NAME Contractor : COMPANY NAME Name of Unit : Drg. No : Member
Bar No.
Dia of Bars
For COMPANY NAME
No. Per Member
No. of Member
Total No of Bars
Cutting Length
Total Length
Shapes
for CLIENT NAME
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Page 42 of 54
NAME OF WORK
COMPANY NAME CONCRETE WORK PROPOSED PROCEDURE NO. : COMPANY / CLIENT / 11 1. PURPOSE : The purpose of this procedure is for supervision of concreting work at site and to ensure that proper quality control is made at site. 2. SCOPE: This procedure covers the work method for placement of concretes. 3. CONTROLLING SPECIFICATION All plain and reinforced concrete works will comply with the requirements mentioned in Technical Specification, IS 456 and approved construction drawing. 4. MATERIALS A) WATER: Water used in concreting shall be clean and free from injurious amounts of solids, acid, alkalis, salts, sugar, organic materials or other harmful substance which may be deleterious to concrete. Portable water shall be considered as satisfactory. Test on water sample will be considered out in accordance with IS 3025 and they shall fulfill all the guidelines and requirements of IS- 456 for curing shall be of same type. B) COARSE AGGREGATES: Coarse aggregates shall confirm in all respect to IS 383 Aggregates shall be obtained from an approval source. Aggregate shall consist of naturally occurring stone (crushed or uncrushed), gravel. These shall be chemically inert strong hard, clean, durable against weathering of limited porosity, free from dust, silt, organic impurities and free from adherent coating reactive silica shall not be used. The maximum size of coarse aggregate shall as state on the drawing but in no case greater than of the minimum thickness of the member. Maximum quantity of harmful materials in aggregate shall not exceed the limit defined in IS: 383. C) FINE AGGREGATES: There shall comply with the requirements of IS:383 Zone IV sand shall not be used. Fine aggregates shall consist of materials resulting from natural disintegration of rock and which has been deposited by stream. The grading of aggregate will confirm to table 1, 2, 3, &4. All in aggregate shall confirm to requirement in table 5. Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
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NAME OF WORK
D) CEMENT : Normally the cement shall be ordinary Portland cement confirming to IS 8112 Test Certificate of the cement of each consignment shall be submitted to CLIENT. E) STEEL MS Reinforcement for cement concrete works will confirm to IS 432 Part – I and high strength deformed bars will confirm to IS 1780 and relevant part of IS 456. Manufacturer’s test certificate (MTC) will be produced for all type of reinforcement steel and for all the batches coming to site. All reinforcement bars will be clean and free from dirt, oil, paints, grease, mill scales and loose rust. F) FORM WORK: The form work will be of plywood or steel plates. The shuttering will be supported on battens and props of ballies cross-braced together. The surface of shuttering in contact with concrete will be given a coating of shuttering oil. Removal of shuttering will be as per IS: 456. 5. PROCEDURE A) PLAIN CEMENT CONCRETE (P.C.C.): For all PCC works, the concrete will be mixed in a approved mechanical mixer in recommended proportions by volume and laid in the foundation. Concrete mixing will be done in the mixer. All concreting works shall conform to the latest edition of IS specifications. B) REINFORCED CEMENT CONCRETE (R.C.C.): For all RCC structure bar bending schedule will be prepared and got received by the Engineer-in-charge if not provided in the drawing. The ingredients will be mixed in a mechanical mixer. The coarse and fine mixing time will not be less than 2 minutes for a mixer of 0.75 cum capacity and 2.5 minutes for a mixer of capacity more than 0.75 cum. The concretes will be transported and placed on a clean bed directly in the form work. Concrete will not be dropped from a height of more than 1.0 m and will laid in position in horizontal layers of not more than 15 cms. The concrete after being laid, will be compacted using needle vibrators. Concrete shall normally be compacted in its final position within 30 minutes of leaving the mixer. Whenever a construction joint to be provided in a monolithic structure, bonding grooves will be formed in the concrete already laid and the surface will be roughened cleaned and given a wash of neat cement slurry before laying new concrete as laid down in Clause 12.4.1 of IS : 456. The concrete will be cured for a minimum period of 7 days. Bending, binding, lapping and placing reinforcement in position will be done as per IS: 456, IS: 2052 and other relevant codes, bars will be cleaned of rust, scales, grease, oil and any other foreign matter before placing in 16 gauge binding wires unless otherwise specification IS: 456 No concreting shall be started prior to approval of placing of reinforcement in position. 6.
INSPECTION
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NAME OF WORK
Coarse aggregates, fine aggregates and water sample used for concreting will be checked in case of change of source, periodic checking will be done in every three months. The weight of cement bags will be checked at random for each batch. Concrete cube sample shall be taken and tested 3 cubes for 7 days and 3 cubes for 28 days. QUANTITY
SAMPLES (6 CUBES OF 15 CUM)
0-5 CUM 6-15 CUM 16-30 CUM 31-50 CUM 51 & ABOVE
1 SET 2 SET 3 SET 4 SET 4 + 1 SET FOR EACH 50 CUM
7. DOCUMENTS: ITP FORMATS
: : : : :
COMPANY / CLIENT / 15 -01 COMPANY / CLIENT / 15 -02 COMPANY / CLIENT / 15 -03 COMPANY / CLIENT / 15 -04 COMPANY / CLIENT / 15 -05
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NAME OF WORK
COMPANY NAME CONCRETE POUR CARD Project:
PROJECT NAME Systemctrical Sub-stations, Electrical Installations, and Generator etc. including Designing ‘DEFERRED PAYMENT’ Basis for CLIENT.
Client: CLIENT NAME Location: Concrete Element & Location: Approved Drawing No.:
Inspection Required on: Date: Time Inspection Request No.: Date: Time
Y=Yes, N=No and Na=Not Applicable S. No.
Name of Activities
1
Method Statement approved
2
Batching Plant/ mixers in working order
3
Standby batcher in working order
4
Water, Coarse aggregate, Cement, Sand, admixture approved
5
Water, Coarse aggregate, Cement, Sand, admixture stock sufficient
6
Concrete conveying arrangement available in working condition
7
Formwork approved
8
Reinforcement approved
9
Concrete gang present: including carpenter, steel fixer, mechanics & electricians
10
Access provided
11
Safety arrangements sufficient
12
Lighting provided
13
Communication between various points provided
14
Arrangements for arranging suspension, stoppage of concrete provided
15
Curing arrangements made
16
Laboratory notified
Contractor’s Engineer
Inspected by: (Contractor’s Engineer) Charge) Name:
Engineer in Charge
APPROVED BY: (Engineer-in-
Name:
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NAME OF WORK
Sig. & Date
Sig. & Date
COMPANY/CLIENT/1501
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NAME OF WORK
CUBE TEST REPORT Project:Agency:Client :Cube ID Mark
PROJECT NAME System.
COMPANY NAME. CLIENT NAME Date of Casting
Location & Detail of Structures
Date of Testing
Age (Day)
Dimension of Cylinder L B H (mm) (mm) (mm)
Area (Sqm)
Wt. Of Cylinder (Kg)
For COMPANY NAME.
Density
Compressive Strength (N/Sqmm)
Avg. Compressive Strength (N/Sqmm)
Remarks
For CLIENT NAME
COMPANY/CLIENT/1502
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NAME OF WORK
COMPANY NAME REINFORCEMENT INSPECTION CHECK LIST Project:
PROJECT NAME System
Client: CLIENT NAME Name of Building: Concrete Element & Location: Approved Drawing No.:
Inspection Required on: Date: Time Inspection Request No.: Date: Time
Y=Yes, N=No and Na=Not Applicable S. No.
Name of Activities
1
Working drawings checked & approved
2
Location revision being used
3
Bar schedules approved
4
Reinforcement steel materials approved
5
Bar bending & cutting satisfactory
6
All corroded bars rejected
7
Bar sizes correct
8
Bar spacing correct
9
Bar lap lengths correct
10
Bar laps at correct location
11
Bar ties are specified and binding wire used
12
Bar assembly rigid and adequately supported
13
All bar crossings tied up with binding wire
14
Cover to bottom bars correct
15
Cover to top bars correct
16
Cover to side bars correct
17
Cover blocks approved including fixing
18
Only approved cover blocks used
19
Quality & size of binding wire approved
Contractor’s Engineer
Inspected by: (Contractor’s Engineer) Charge) Name: Sig. & Date Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
Engineer in Charge
APPROVED BY: (Engineer-in-
Name: Sig. & Date Page 49 of 54
NAME OF WORK
COMPANY/CLIENT/15-03
COMPANY NAME POST CONCRETE CHECK LIST Project:
PROJECT NAME System.
Client: CLIENT NAME Name of Building: Concrete Element & Location: Approved Drawing No.:
Inspection Required on: Date: Time Inspection Request No.: Date: Time
Y=Yes, N=No and Na=Not Applicable S. No.
Name of Activities
1
Concrete Started on
2
Concrete completed on
3
Curing Satisfactory
4
Cube Strength
5
Concrete surface condition
6
Any repairing required
Contractor’s Engineer
Engineer in Charge
Remarks for rectification by Engineer-in-Charge
Concrete quality Acceptable : Yes/No
Inspected by: (Contractor’s Engineer) Charge) Name: Sig. & Date
APPROVED BY: (Engineer-in-
Name: Sig. & Date
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NAME OF WORK
COMPANY/CLIENT/15-04
COMPANY NAME SLUMP TEST REGISTER Name of the Project : PROJECT NAME System
Client : CLIENT NAME Contractor : M/s COMPANY NAME.
S.NO.
Date/Time
Mix/Grade of Concrete
Location of Concrete Pouring
Slump in mm
Contractor's Engineers Sign.
ENGINEER-IN -CHARGE
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NAME OF WORK
COMPANY NAME
CANAL WORKS PROPOSED PROCEDURE NO.: COMPANY/CLIENT/12 1. Scope: This procedure covers the work method for Excavation, Bed Lining and short creating of Canal works 2. Method: Excavation: After line out the area as per lines and levels shall be barricading by suitable means for protection against risk of accident due to open excavation sufficient safety measures such as red light at night will be placed at suitable interval. Excavation adjacent to service line in congested area shall be done manually, otherwise trenching shall be carried out by equipments. Depending upon the depth of excavation and nature of soil the trench shall be shored wherever necessary and kept dry so that the workmen can work therein safety and efficiently. The discharge of the trench dewatering pumps shall be conveyed either to drainage channels or to natural drains and shall not be allowed to spread in the vicinity of the worksite. Open cut trench shall be barricaded to protect the life, property or the work. When closed sheeting is required, it shall be so driven as to prevent adjacent soil for entering the trench either below or through. While carrying out excavation work the excavated material/earth shall be placed at least 3 meter away from the trench edges or ½ of the trench depth, whichever is more. All excavated material shall be stacked in such a manner that it does not endanger the work and avoids obstructing laying works. Natural water courses shall not be obstructed. During construction work if it is necessary to close the road, suitable signs indicating that a road is closed shall be placed and necessary diversion signs for proper maintenance of traffic shall be provided. Trees, shrubbery fences and other properties shall be protected unless their removal is shown in the drawing. Where trees have been cut, the tree roots within a distance of half meter from the side of the pipeline shall be removed or killed. Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
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NAME OF WORK
However if over excavation is done particularly where rock is encountered then the over excavation shall be made up as follows: a. In the Bed
: Over excavation shall be filled with gravel and aggregates.
b. For the Sides : Over excavation shall be filled with lean concrete 1:4:8 CONCRETE The concrete will be mixed in a approved mechanical mixer in recommended proportions by volume and laid in the foundation. Concrete mixing will be done in the mixer. All absorptive surfaces against which concrete is to be laid shall be moistened thoroughly so that moisture will not be withdrawn from freshly placed concrete. Before placing the concrete the surface shall be free from standing water and mud and 1:3 cement slurry may be spread over the moist sub grade. If the concrete is laid by manually on the bottom of canal it should be in panel of 3m with suitable joint in between. The joint shall be filled with sealing compound conforming to IS 5256, concrete shall be compacted with screed vibration. SHOTCRETE WORKS Shotcrete shall be applied to sides of canal excavations as per drawing and approval of Engineer. Contractor will submit design mix. Materials: Cement
: Ordinary Portland cement conforming to IS 8112
Aggregates
: As per IS 383. (The size of coarse aggregate is restricted to 10mm).
Admixtures
: Super plasticizers- Shall meet the requirements of ASTM C 494 type F Shall be compatible with cement & Accelerator Accelerators- Only liquid accelerator shall be used. The max. dosage shall be 6% (by mass of cement).
Procedure : All unsound and deteriorated concrete be removed and chipping done, wherever necessary, or sand blasting done. Exposed reinforcement bars be cleaned free of rust/scales. Additional reinforcement is provided if any as warranted. Ensure sufficient
3. INSPECTION The alignment and levels of the canal will be checked as per the drawing. 4. CURING. Name of Company Methodology & Quality Assurance Plan Print to PDF without this message by purchasing novaPDF (http://www.novapdf.com/)
Page 53 of 54
NAME OF WORK
On completion of laying concrete lining and after a period of 24 – 36 hours, the lining shall be cured in conventional manner with water by making small earthen bunds of say 150mm to 200mm height with ponding water for at least 28 days or as per IS code. The side walls will be cured with water retaining gunny bags which will be kept continuously moist by spraying water manually.
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