Doc No. :-MMRCL/NCCL/SISCOL/CGRP&CGHB/QAP/008 Date:- 10.10.

2018 Page No : 1 of 7

QUALITY ASSURANCE PLAN

Fabrication of Composite Girders at Nashik Phata for Pune Metro Rail Project And
BRIEF DETAILS OF THE PROJECT:- Fabrication of Composite Girders at Harish Bridge for Pune Metro Rail Project

NAME OF WORK:- Fabrication of Composite Girder 43.5m at Nashik Phata And 25.1m, 43.5m, 45.75m at Harish Bridge.

GOVERNING SPECIFICATION:- IRS Welding Bridge & BS 110 Issued By RDSO Lucknow

ROLES & RESPONSIBILITIES OF

VARIOUS AGENCY INVOLVED IN
MMRCL, GC, SPA, NCCL, SISCOL
FABRICATION, ERECTION &
INSPECTION:-

CLIENT NAME:- MAHARASHTRA METRO RAIL CORPORATION LIMITED

CONTRACTOR NAME:- NAGARJUNA CONSTRUCTION COMPANY LIMITED

FABRICATING AGENCY:- M/s. STEEL INFRA SOLUTIONS PVT LTD, BHILAI-490026 (CHHATTISGARH)

GENERAL ARRANGEMENT DRAWING NO.

P1D02-SPA-CV-BAS-103-00-00-DGA-2001 Rev. B13

DRAWING REFERENCES:- FOR NASHIK PHATA

P1D02-SPA-CV-BAS-103-00-00-DGA-2002 Rev. B13

P1D02-SPA-CV-BAS-107-00-00-DGA-2003 Rev. B06 FOR HARISH BRIDGE

SUBMITTED BY:- M/s. STEEL INFRA SOLUTIONS PVT LTD, BHILAI-490026 (CHHATTISGARH)

Signature of Signature of Contractor DDC GC Client

Fabricating Agency NCCL SPA MMRCL
SISCOL

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 Doc No. :-MMRCL/NCCL/SISCOL/CGRP&CGHB/QAP/008 Date:- 10.10.2018 Page No : 2 of 7

QUALITY ASSURANCE PLAN (QAP)

SN Component / Oprerations
1 2
Inspection Detail
Frequency &Type of Reference Fabrictors Quality
Characteristic check Type of Record Acceptance Criteria Remarks
check Documents Control Extent of
Inspection Agency
Inspection
3 4 5 6 7 8 9 10 11

1.0 Raw Material

Plates: IS 2062-2011, Gr. E

350 BO, 12mm & above thick.
Verification of mill Plates are fully killed &
Identification and Representative All raw material will be supplied by
T.C. for all Verification normalized or control cooled
Steel Plates & Rolled correlation with Mill Challan, from Fabricator’s SAIL,TISCO,ESSAR,RINL,JINDAL or
heat/casts from of reference And UTquality as per IS 4225
1.1 (Channel, Angle,Beam) Test Certificate from Mill T.C. MMRCL/GC/NCCL 100% record from RDSO approved sources only. Raw
RDSO/NABL document or ASTM A435 or ASTM A578.
Steel Section Supplier listed by or nominated Material clearance by inspection
approved labs Structure Rolled Sections
MMRCL agency authority.
(Channel, Angle,Beam As Per
IS 2062-2011, Gr. E 250
BO/A/BR

Representative
Material condition i.e.,
Visual from Fabricator’s
Pitting, rusting,
Visual IS 2062-2011 Inspection MMRCL/GC/NCCL 100% Record IS 2062-2011
straightness, rolling
or nominated
defect, etc.
agency

Signature of
Fabricating Agency Signature of Contractor DDC Client
SISCOL NCCL SPA GC MMRCL

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 Doc No. :-MMRCL/NCCL/SISCOL/CGRP&CGHB/QAP/008 Date:- 10.10.2018 Page No : 3 of 7

UTS,YS,%EL,Bend Representative
test as per IS 2062- from Fabricator’s IS 2062-2011, Gr. E 350 BO
Manufacturers Satisfactory test 12mm and above thick BO grade
1.2 Raw Material 2011 and for 12mm MMRCL/GC/NCCL Record for plates & Angle,
Test Certificate for report of lab material to be test at 0℃ for Impact
thick and above Lab Test at NABL or nominated Channel,Beam E250BO/A/BR
charpy at 0℃ steel plates. the agency
accredited
material to be
approved
offered heat/cast
Laboratory/Gov.ap Heat Wise
no. wise & if the
roved lab for all
same is not Representative
heats by
Chemical test for available then from Fabricator’s
inspection agency Satisfactory test
C,P,Si,S,Mn as per IS testing will be MMRCL/GC/NCCL Record
done plate wise. report of lab
2062-2011 or nominated
agency

UT at works for 12mm Representative

IS 4225/ASTM SA Ultrasonic test per heatwise min 50%
and above thick plates atisfactory test from
By ASNT Level II Test REport 435/435M or * if already UT Certified by
as per IS-4225/ASTM report by ASNT MMRCL/GC/NCCL 100%
operator Maintain ASTM SA 578/578M manufacturer UT at work should be
SA-435/435M/ASTM level-II operator or nominated
done 50% per heat.
A578. agency

Representative
100%
from Fabricator’s
All Material Measurement
Dimension Challan MMRCL/GC/NCCL 100% Record as per IS-1852 for tolerence
Measurement, of Dimension
or nominated
agency

Visual/ DTI washers should be used to indicate

Stud, HSFG Bolt, Nut &
1.3 a) Dimensions Measurement that the required tension is achieved for
Washer Fabricator's
Representative As per IS: 2062-2011 HSFG bolts
Verification of Record & NABL
from As per for stud ISO: 13918,BS-
Reference accredited
Challan MMRCL/GC/NCCL requirement 115R1 & for HSFG Bolts IS:
Lab test at NABL Document approved
or nominated 3757, BS-111R5, IS: 4000-
accredited Laboratory/Gov.a
b) Test as Per agency 1992
approved pproved lab
Specification
Laboratory/Gov.ap
proved lab

Signature of
Fabricating Agency Signature of Contractor DDC Client
SISCOL NCCL SPA GC MMRCL

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 Doc No. :-MMRCL/NCCL/SISCOL/CGRP&CGHB/QAP/008 Date:- 10.10.2018 Page No : 4 of 7
Manufacturer’s
Batch
Test Certificate & Paints to be procured from
Verification of Batch wise NABL accredited IS 104, IS 2074, IS 2339, IS vendors approved by RDSO/ISI Mark
1.4 Paints & Metalizing Manufacturer’s Test manufacturing test approved 5666 & 3mm to 5mm Al.Wire Paint
Certificate, certificate Representative Laboratory/Gov. with 99.5% purity Shear Stud Should not be
Vefification of
Challan., from approved lab test painted
Reference
Manufacturer’s MMRCL/GC/NCCL Batch Wise certificate
Document
Test Certificate or nominated
Lab test at NABL agency
accredited IS 104, IS 2074, IS 2339, IS
Tests as per Lab. Test Report Sample testing to be done as per
approved 5666, Contract agreement
Specification IS:101
Laboratory/Gov.ap
proved lab

Challan., Representative
Verification of
Welding As per specification Any test as Manufacturer’s from As per Fabricator’s Consumables
Reference
1.5 Consumables and as approved by required Batch Test MMRCL/GC/NCCL requirement Record & MTC As per IRS; M28, M39 & M46 should be of RDSO appvd.Brand
Document
RDSO Certificate or nominated
agency

Manufacturing Process
2.0

Representative
100%
Measurement with Approved from Relevant IS/IRS Codes &
Measurement
2.1 Nominal Layout Dimensional Accuracy calibrated steel Drawing MMRCL/GC/NCCL 100% Inspection Report Approved Drawings
of Dimension
tape & gauges or nominated
agency
As per Requirement
Representative
100%
Measurement with Approved from Relevant IS/IRS Codes &
Measurement
Camber Layout Dimensional Accuracy calibrated steel Drawing MMRCL/GC/NCCL 100% Inspection Report Approved Drawings
of Dimension
tape & gauges or nominated
agency

Representative
Dimensional Accuracy Visual 100%
Jigs, Fixtures & Approved from Record of Jigs
& Intersection lines, Measurement Measurement IRS B1-2001
Templates Drawing MMRCL/GC/NCCL 100% & fixtures as
pitch, gauge, dia. Of using calibrated of Dimension
or nominated per pIRS-B1
Holes & No. of holes steel tape
agency
Preparatory works:-
1. Cutting,
2.
100%
Straightening, Representative
verification of
3. Edge Preparation, 100% Checking & from Fabricator's
Dimension, Freedom Visual Dimension Approved Drawing records and IRS B1-2001
2.2 4. Marking, Records in MMRCL/GC/NCCL Record &
from defect s & proper jig & IRS B1 checking
5. Drilling, Register or nominated Inspection Reports
when
6. Fitup, agency
necessary
7. Pre-
Assembly,
8. EndFinishing

Signature of
Fabricating Agency Signature of Contractor DDC Client
SISCOL NCCL SPA GC MMRCL

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3.0 Welding

Representative
IRS B1-2001
Review of from Fabricator’s IRS B1-2001 IS 9595-96 Only RDSO Certified welders to be
IS 9595-96 100% of items in
3.1 WPSS WPSS Verification MMRCL/GC/NCCL 100% Record WBC- 2001 engaged
WBC-2001 column 3
or nominated in the job.
agency

Fabricator's
Representative
Witnessing of Record [WPQR
Visual, DT, As per code from Only RDSO Certified welders to be
established WPSS 100% of items in Sheet to be IS 7310(I)-74
3.2 WPQR NDT as per code requirement MMRCL/GC/NCCL 100% engaged
Witnessing of Welder column 3 recorded in
requirement or nominated in the job.
Qualification test presence of
agency
Representatives]

Fabricator's
Representative
Verification of Record [WPQR
As per approved from
Measurement of Visual with Reference Sheet to be IRS B1-2001
3.3 Preheating WPSS MMRCL/GC/NCCL Random
Temperature thermal Chalk Documents recorded in
or nominated
presence of
agency
Representatives]

Visual Check of As per

Baking of Electrode, Flux To have moisture free
3.4 Electrodes & Manufacture’s Verification of Representative
Electrode & Flux Fabricator's As per RDSO approved vendors list
beating recommendations Reference from
Record [To be IRS B1-2001, IRS:M39 & M28 without RDSO approved brand
Documents and MMRCL/GC/NCCL 100%
verified by consumable to be test at NABL
checking of items or nominated
Representatives] approved lab
Selection of correct Reference to WPSS, As per approved in column 3 agency
3.5 Visual
Electrodes & Flux IRS Class, etc. WPSS

Representative
Fabricator's
Visual with Verification of from
Measurement of Amp. As per approved Record [To be
3.6 Current Condition Ammeter & Reference MMRCL/GC/NCCL Random IRS B1-2001 & WBC
& Voltage WPSS verified by
Voltmeter Documents or nominated
Representatives]
agency

Representative
Fabricator's
Verification of from
As per approved Record [To be
3.7 Sequence of Welding To control distortion Visual Reference MMRCL/GC/NCCL Random IRS B1-2001
WPSS verified by
Documents or nominated
Representatives]
agency

Representative
Fabricator's
Verification of from
Provision of Run-on & Free from crater As per IRS B1- Record [To be
3.8 Visual Reference MMRCL/GC/NCCL Random WBC & Approved Drawing
Run off Plates defects 2001 verified by
Documents or nominated
Representatives]
agency

Signature of
Fabricating Agency Signature of Contractor DDC Client
SISCOL NCCL SPA GC MMRCL

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Representative
Visual Inspection &
from
a) For Fillet Welds Visual, Gauge & Approved Drg. & Verification of Fabricator’s Relevant IS/IRS Code, Clearance shall be given by Inspection
MMRCL/GC/NCCL 100%
Visual, Fillet Size, Macro Etching. WPSS dimension by Record Approved Drg. & WBC- 2001 authority
or nominated
gauges
agency

Representative
Inspection of from
4.0 Welding b) DP Test For Fillet Approved Drg. & Visual Inspection & Fabricator’s Relevant IS/IRS Code, Clearance shall be given by Inspection
Visual MMRCL/GC/NCCL 100%
Weld WPSS 100% Checking Record Approved Drg. & WBC- 2001 authority
or nominated
agency

Representative
Visual Inspection &
from
Visual, Gauge & Approved Drg. & Verification of Visual 100% Fabricator’s Relevant IS/IRS Code, Clearance shall be given by Inspection
c) For Butt Weld MMRCL/GC/NCCL
RT/UT WPSS dimension by RT/UT 25% Record Approved Drg. & WBC- 2001 authority
or nominated
gauges
agency

a) Camber on Jack
b) Dead Load
deflection
c) Representative
Dimension 100% Dimensional from One Fabricator's Further spans need not to trial
Visual & Approved. Drg.
5.0 Trial Assembly d) Fairness of holes Check of Control MMRCL/GC/NCCL complete Record & IRS B1-2001, BS-110 assembled if same jig are used in
Dimensional IRS-B1 & BS-110
e) Temporary Assembly or nominated span Inspection Report previous span fabrication work.
fasteners agency
f) Infringement
g) Butting of
compression edges

Representative
from Initial inspection and final Clearance by
Acceptance & Clearence Erection mark for all Visual Dimensional Approved Drg. & IRS B1-2001 & BS-110
6.0 Dimensional Check MMRCL/GC/NCCL 100% Inspection Report NCC/Consultant/Client/TPI
for Painting component & Structural IRS B1
or nominated
agency

The surface should be

throughly cleaned &
Representative
roughness by 1st coat-IS:5666,
Perform, Inspect from 1st coat- 10 microns, 2nsd
Surface preparation & compressed air 2nd coat-IS:104, Painting should not be done durng rainy
7.0 Visual & maintain MMRCL/GC/NCCL Random As per IRS B1 coat-35 microns, Finish coat-
Painting blasting with a Finish coat- season or humidity condition
records or nominated 20 micron (min)
suitable abrasive IS:2339
agency
material like grit,
copper slag

Signature of
Fabricating Agency Signature of Contractor DDC Client
SISCOL NCCL SPA GC MMRCL

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8.0 Paints & Metalizing
At least one layer of
coating must be
applied within 4 hours
Representative
of blasting & the
Visual & coating to Perform inspection visual & coating to from For aluminium wiree & MTC should be
Metal Spraying by wire surface must be to be records in in accordance to clause-2 of
8.1 be checked by & maintain be checked by MMRCL/GC/NCCL Random covered 99.5% aluminium conforming
method completely coated to register appendix VII of IRS-B1
elcometer records elcometer or nominated to IS:2590.
be specified thickness
agency
within 8 hours of
blasting (normal
coating 150 microns)
Representative
from
to be records in
8.2 Etch Primer One coat to be used Visual checking Maintain Records Visual Checking MMRCL/GC/NCCL Random As per IRS_B1
register
or nominated
agency

Representative
Procured from RDSO approved sources
One Coat to be used visual & coating to Visual & coating to from
to be records in only Painting should not be done during
8.3 Zinc Chromate (IS:104) (Normal coating 25 be checked by Maintain Records be checked by MMRCL/GC/NCCL Random As per IRS_B1
register rainy season or humidity condition.
microns) elcometer elcometer or nominated
agency
Representative
Two coat to be used
visual & coating to Visual & coating to from
Aluminium Paint (Normal coating 30 to be records in
8.4 be checked by Maintain Records be checked by MMRCL/GC/NCCL Random As per IRS_B1
(IS:2339) microns_minimum 15 register
elcometer elcometer or nominated
microns in each coat)
agency
Representative
Shipping mark to be from
Final Clearance for Shipping mark as to be records in
8.5 done for all Visual Maintain Records MMRCL/GC/NCCL Random As per IRS_B1
Dispatch per Drawing register
components or nominated
agency

Signature of
Fabricating Agency Signature of Contractor DDC Client
SISCOL NCCL SPA GC MMRCL

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