SIMPLEX INFRASTRUCTURES LIMITED

NOAPARA-BARANAGAR-DAKHINESWAR METRO RAILWAY PROJECT, KOLKATA

CONSTRUCTION OF PSC VIADUCT, EMBANKMENTS AND STATIONS INCLUDING E&M WORKS IN CONNECTION WITH EXTENSION OF METRO RAILWAY LINE BETWEEN CH: 2591M TO CH:6373M FOR NOAPARA
(EXCLUDING)-BARANAGAR-DAKHINESWAR OF KOLKATA METRO IN THE STATE OF WEST BENGAL, INDIA

INSPECTION & TEST PLAN - STEEL STRUCTURE WORK FOR STEEL BRIDGE AND METRO STATION

ITP REF: 012/SIL/RVNL/C 3004/VOL.1/05 DATE: 20/02/2015

SCOPE OF
REFERENCE INSPECTION
SL. DESCRIPTION OF FREQUENCY OF
CHARACTERISTICS TYPE OF CHECK ACCEPTANCE CRITERIA DOCUMENTS / REMARKS
NO. MATERIALS CHECK
SPECIFICATION
SIL RVNL

1 Incoming Inspection of Raw Materials and Bought Out Items

Dimension Measurement 100% As per drawing

Physical Appearance Visual Inspection 100% No pitting & heavy rusting.

Structual steel girder conforming to FE

Mechanical Tests - UTS, 410B(O) as per IS:2062- 2011 Grade B
Yield stress, elongation & Verify MTC and for cross frame the steel shall MTC, Challlan, Lab Test
1.1 Steel plates & Rolled Sections W R
bend test & Impact test MTC-100% and Lab Test: confirm IS 226-1975 for steel bridge. Report & Site Register
Built up sections are made from hot
One sample for each
rolled plates confirming to ASTM A 572
Invoice . Gr 50 ( 345 MPA) steel Hot rolled
sections except beams are mill section
complying with IS 2062 for 240 MPA
yield for station structures.
Chemical Properties Verify MTC

UT at site: One sample

As per ASTM 578 level B & Test
UT Visual for each Heat No in >/=
Report
20mm thk.

For GMAW: SFA/AWS A 5.18 ER-

Welding Filler Wire / Electrodes / challan & Batch Test 70S-6 / For SAW: SFA/AWS 5.17 Site Register / Batch Test
1.2 Specification 100% W R
Flux etc. Certificate EM-12-K / For SMAW: SFA/AWS 5.1 Certificate
E-7018.

Dimension Measurement One sample in every lot As per drawing

MTC, Challlan, Lab Test

1.3 HSFG Bolts, Nuts & Washers W R/W
Report & Site Register
TC-100% and Lab Test:
Mechanical Properties Verify MTC IS: 1367 Part-III & Test Report
One sample per Invoice .

Client Specification / Approved Site Register / Batch Test

1.4 Primer & Paints Specification Batch Test Certificate 100% W R
technical literature of manufacturer. Certificate
 SCOPE OF
REFERENCE INSPECTION
SL. DESCRIPTION OF FREQUENCY OF
CHARACTERISTICS TYPE OF CHECK ACCEPTANCE CRITERIA DOCUMENTS / REMARKS
NO. MATERIALS CHECK
SPECIFICATION
SIL RVNL

Dimension Measurement Random

Client Specification / Relevant MTC, Challlan, Lab Test
1.5 Stud Shear Connector W R
MTC-100% and Lab Test: Code. Report & Site Register
Mechanical Properties Test Certificate One sample for each
Batch / Lot.
2 Pre-Manufacturing Process

SAW Visual, NDT and DT 100%

Inspection Reports / NDT

Procedure Qualification Record
2.1 SMAW Visual, NDT and DT 100% AWS D1.1 / Technical Specification Reports / Lab Test W W&R
(PQR)
Certificate

GMAW Visual, NDT and DT 100%

SAW Verify Approved PQR 100%

Welding Procedure Specification

2.2 SMAW Verify Approved PQR 100% AWS D1.1 / Technical Specification Approved WPS W W&R
(WPS)

GMAW Verify Approved PQR 100%

Visual Verify Approved WPS 100%

Data Sheet / NDT Reports /
2.3 Welder Qualification Test AWS D1.1 / Technical Specification Welder's Certificate & ID W W&R
Card
NDT Verify Approved WPS 100%
 SCOPE OF
REFERENCE INSPECTION
SL. DESCRIPTION OF FREQUENCY OF
CHARACTERISTICS TYPE OF CHECK ACCEPTANCE CRITERIA DOCUMENTS / REMARKS
NO. MATERIALS CHECK
SPECIFICATION
SIL RVNL

3 Manufacturing Process

Dimension Measurement 100%

3.1 Marking As per approved drawing Dimension Report W R

Marking Measurement 100%

3.2 Cutting Dimension Measurement Random As per approved drawing Dimension Report W R

3.3 Layout of Components & Joints Dimension Visual & Measurement 100% As per approved drawing Inspection Report W W&R

3.4 Jigs, Fixtures & Templates Dimension Visual & Measurement 100% As per approved drawing Approved Drawing W R/W

Edge Preparation of
Visual 100%
Joints

3.5 Fit up Dimension Measurement 100% As per approved drawing Fit up inspection Report W W&R

Temporary Support to
Visual 100%
avoid Distortion

Welding Parameters
Approved WPS / As per
(Current, Voltage, Travel Random
job requirement
Speed etc.)

Consumables
(Electrodes, Filler Wire, Specification 100%
Flux etc.)
3.6 Welding As per approved WPS Internal inspection Report W W&R
Approved Welder's
Welder's Identification 100%
Certificate & ID Card

Approved WPS Visual 100%

 SCOPE OF
REFERENCE INSPECTION
SL. DESCRIPTION OF FREQUENCY OF
CHARACTERISTICS TYPE OF CHECK ACCEPTANCE CRITERIA DOCUMENTS / REMARKS
NO. MATERIALS CHECK
SPECIFICATION
SIL RVNL

Dimension Measurement 100%

Visual Inspection Visual 100%

Distortion Visual & Measurement 100%

Final Inspection Report /
3.7 Final Inspection As per approved drawing W W/R
Approved Drawing
Alignment Measurement 100%

Weld Size Weld Gauge Random

Finishing Visual 100%

100% for Groove Joints &

DPT Visual As per AWS D1.1 Site Register / DPT Report W W&R
20% for Fillet Joints.

100 % for bevel butt joint

3.8 NDT UT Visual As per AWS D1.1 Site Register / UT Report W W&R
in case of Bridge Girder

Random as per available

RT ……… position in case of Bridge As per AWS D1.1 Site Register / UT Report W W&R
Gireder only

Dimension Visual & Measurement 100%

Hole Matching Visual Random

3.9 Trial Assembly As per approved drawing / IS:7215 Inspection Report / Protocol W W

Camber Visual & Measurement 100%

Straightness Measurement 100%

 SCOPE OF
REFERENCE INSPECTION
SL. DESCRIPTION OF FREQUENCY OF
CHARACTERISTICS TYPE OF CHECK ACCEPTANCE CRITERIA DOCUMENTS / REMARKS
NO. MATERIALS CHECK
SPECIFICATION
SIL RVNL

4 Surface Preparation and Painting

Primer
Avg. DFT (As per
Minimum 3 point for each
4.1 Painting manufacturer As per contact specification Painting Inspection Report W R
mark No
specification)
Final Coat

As per approved drawing & control

5 Match Marking Visual Inspection Visual Random Dispatch Clearance Report W R
assembly

Legend :
W – Witness , R – Review, R/W - Review or witness, DFT – Dry Film Thickness, UT – Ultrasonic test, DT-Destructive test, RT – Radiography test, MTC – Manufacturer test Certificates.
DPT – Dye Penetration test, NDT-Non Destructive Test