1. GOVERNMENT OF TAMIL NADU HIGHWAYS DEPARTMENT HIGHWAYS RESEARCH STATION Training program for newly recruited Assistant Engineers

2. Quality control and Assurance of Highway Projects
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3. QUALITY
Totality of features and characteristics of a product for service that bears on its ability to satisfy the projects functional requirements.
The quality of output is always agreed upon between the contractor and the employer
The quality objective is to achieve zero defects with best quality of the project works.
Possible only by ensuring quality control at every stages during progress of construction.
Quality is conformity to standards and requirements to achieve excellence and economy.

4. QUALITY CONTROL
The operational techniques or a system of maintaining standards by reviewing, checking, inspecting and testing
Product oriented and focuses on defect identification
Set of activities to ensure quality in the work. The activities focus on identifying defects in the actual work done.

5. QUALITY ASSURANCE
All actions taken to ensure that standards and procedures are followed to and that delivered products or services meet performance requirements.
Process oriented and focuses on defect prevention
Set of activities to ensure quality in the process by which works are done.
The goal of QA improve and develop test processes so that defects do not arise when the work is being done.
The well designed quality assurance system will provide confidence that the project outputs will fulfil all the requirements for which it is being planned.

6. Quality assurance system basic parameters.
Site documents
Mandatory and optional testing
Availability of field and departmental laboratories
Manufacturing test certificates
Departmental team inspections Checklist guide for works
Site inspections
Post quality testing of finished works Quality certification
Monthly reporting and review meetings

7. Benefits of QC/QA Improved quality Uniformity
Economic utilization of materials
Reduction in user cost
Additional cost – Fraction of resulting benefits
0.5 to 1% of construction cost

8. Requirements for good QC practices
Well prepared estimates based on field tests and established test procedures
Provision for quality control in estimates
Staff with adequate training and knowledge
Adequate QC equipments and lab facilities
Periodical review and appraisal of QC data
Updating of knowledge

9. Causes of non-conforming works
Lack of training
Lack of resources
Poor communication / incomplete instructions
Inadequately defined work practices
Inadequate supervision
Inadequate planning and
Non maintenance of records
Lack of involvement

10. Quality control methodology
Control of Materials
Test Procedure
Frequency
Acceptance Criteria
Corrective actions
Equipments and calibration
Documenting the results

11. Estimate stage considerations
Get required test results and data (CBR, BBD & Traffic census)
Avoid manipulation and errors
Make uniform provisions along and across the road
Adequate provisions for shoulder and drain
Include geometric components and corrections

12. QC requirements Testing of materials Manufacturing/mixing process
Tests during laying/finishing

13. QC requirements Material to be used Methodology to be adopted
Works to be performed
Shall be as per specifications

14. MORTH Section 900 (QC) Highlights
Field laboratory manned by qualified Civil Engineer shall be provided by the contractor
Contractor shall carry out QC tests on the materials and work to the stipulated frequency
The contractor shall provide necessary cooperation and assistance in obtaining samples for tests and carrying out field tests including lab equipments, transportation, consumables and personnel.
Works found falling short of quality shall be rectified by the contractor at his own cost
The cost of the above provisions and services shall be deemed to be incidental to work

15. Control of Alignment, Level and Surface Regularity
Works shall conform to the lines, grades and cross sections shown in the drawings
The edges of the carriageway shall be correct within a tolerance of ±10 mm, for lower layers of pavement it is ±25 mm
The levels of subgrade and other pavement layers shall not vary from those calculated with reference to the LS & CS of the road swhon on the drawings
For subgrade permitted tolerance in surface levels is ±20 mm, for flexible pavement sub base it is ±10 mm, for manually laid base course it is ±15 (machine laid ±10 mm) and for bituminous base/binder course/wearing course it is ± 6 mm
For BC surface the permissible value of roughness is 2000 mm/km.

16. Typical flow chart for quality control in road works
Source: Quality Assurance Handbook for Rural Roads

17. Typical flow chart for quality control in road works
Source: Quality Assurance Handbook for Rural Roads (contd...)