Prepared in accordance with IRC SP-84 and MORTH/NHAI EPC Guidelines
1. Introduction
This guide integrates IRC SP-84 standards and MORTH/NHAI’s Engineering, Procurement, and Construction (EPC) model to streamline contract administration and project management for highway/expressway projects. It emphasizes:
- Regulatory compliance with IRC and EPC guidelines
- Risk mitigation strategies to prevent delays and cost overruns
- Quality control measures to ensure durability and safety
- Efficient project execution through structured contract administration and project management
This guide is structured to help professionals manage contracts, ensure quality control, monitor execution, and resolve disputes effectively.
2. Contract Administration Principles
2.1 Roles and Responsibilities
2.1.1 Employer (MORTH/NHAI)
- Approves project designs and ensures statutory compliance
- Monitors project progress and enforces contract conditions
- Certifies payments and evaluates contractor performance
- Ensures land acquisition and statutory clearances
- Resolves disputes as per EPC Clause X
2.1.2 Contractor (EPC)
- Single-point responsibility for design, procurement, construction, and defect liability
- Ensures compliance with IRC SP-84 (e.g., pavement, structures, materials)
- Submits progress reports, quality assurance plans (QAP), and safety plans
- Engages sub-contractors/vendors with MORTH/NHAI approval
2.1.3 Consultant (Independent Engineer)
- Conducts independent quality audits and progress verification
- Reviews designs, materials, and workmanship
- Provides technical support to the employer
- Approves or rejects contractor submissions based on IRC standards
2.2 Contract Mobilization
- Performance Security: Contractor submits 5–10% of contract value as security
- Mobilization Advance: Paid to the contractor to facilitate initial project setup
- Site Possession Certificate: Issued upon completion of land handover (EPC Clause Y)
2.3 Payment Mechanisms
- Milestone-based Payments: Linked to project progress (e.g., embankment, pavement layers)
- Retention Money: 3–5% withheld until completion and final acceptance (EPC Clause Z)
2.4 Variations and Change Orders
- Process:
- Contractor submits scope change proposal
- Employer/Consultant reviews cost/time impact
- Negotiation and issuance of Variation Order (EPC Clause A)
- IRC SP-84 mandates documentation and justification for all changes
2.5 Dispute Resolution
- Hierarchy of Resolution:
- Negotiation → Mediation → Arbitration (as per EPC Clause B)
- IRC SP-84 recommends time-bound dispute resolution to prevent project delays
3. Project Management Framework
3.1 Initiation Phase
- Contract Award: Ensuring compliance with EPC terms (lump-sum, fixed timelines)
- Kickoff Meeting: Align stakeholders, discuss project schedule, and define reporting structure
3.2 Planning Phase
3.2.1 Design Management
- Contractor submits detailed design reports compliant with IRC SP-84
- Employer reviews and approves designs within 30 days (EPC Clause C)
3.2.2 Procurement Plan
- Use of MORTH-approved vendors for critical materials (bitumen, steel, cement)
- Scheduling tools: Critical Path Method (CPM), Gantt charts, and Work Breakdown Structures (WBS)
3.3 Execution Phase
3.3.1 Construction Management
- Daily tracking of work progress, material delivery, and compliance with project schedules
- Strict adherence to IRC SP-84 for construction (e.g., compaction, curing periods)
3.3.2 Health, Safety, and Environment (HSE) Compliance
- Implementation of safety management plans
- Environmental safeguards: Dust control, noise reduction, and waste management
3.4 Monitoring and Control
3.4.1 Quality Assurance (QA) & Quality Control (QC)
- Third-party testing labs for materials (IRC SP-84 Table X)
- Non-Conformance Reports (NCRs) issued for deviations (EPC Clause D)
3.4.2 Risk Management
- Common risks: Land acquisition delays, monsoon disruptions
- Mitigation strategies: Contingency planning as per IRC SP-84 Section Y
3.5 Closure Phase
- Commissioning: Final inspections, submission of as-built drawings, and trial runs (IRC SP-84 Annexure Z)
- Defect Liability Period (DLP): 1–2 years post-handover (EPC Clause E)
- Final Payment: Retention money released after defect rectification
4. Quality Control & Quality Assurance (QA/QC) Framework
4.1 Quality Assurance Plan (QAP) Components
- Material Testing: Aggregate gradation, bitumen viscosity, concrete strength tests
- Workmanship Audits: Pavement thickness, compaction control, curing measures
- Inspection Checklists: Ensure compliance with design and contract specifications
4.2 Types of Quality Control Methods
4.2.1 Laboratory Testing
- Aggregate Impact Value, Los Angeles Abrasion, Bitumen Penetration Tests
- Concrete Cube Testing (7-day, 28-day strength)
4.2.2 Field Testing
- Density Control Tests (Field Density Test using Sand Replacement Method)
- Pavement Surface Tests (Benkelman Beam Deflection Test)
- Bridge Load Tests for structural integrity
4.2.3 Non-Destructive Testing (NDT)
- Ground Penetrating Radar (GPR) for pavement thickness assessment
- Ultrasonic Pulse Velocity (UPV) for concrete quality assessment
5. Documentation & Reporting
5.1 Essential Project Documents
- Contract Documents (EPC Agreement, BOQ, Specifications)
- Daily Progress Reports (DPRs)
- Quality Control Reports (Material test results, site inspection logs)
- Safety Compliance Reports
5.2 Digital Project Management Tools
- Building Information Modeling (BIM) for design collaboration
- Enterprise Resource Planning (ERP) for real-time cost monitoring
- Drones & GIS Mapping for topographic surveys and progress tracking
6. Key Best Practices
- Maintain Detailed Documentation: Logs for daily progress, inspections, and stakeholder meetings
- Regular Stakeholder Engagement: Meetings with authorities, communities, and contractors
- Technology-Driven Oversight: Use of drones, IoT sensors, and AI-powered analytics
7. References
- IRC SP-84: Standard Specifications and Code of Practice for Highway Projects
- MORTH/NHAI EPC Agreement: Model Engineering, Procurement, and Construction Contract
- Relevant IS Codes: IS 456 (Concrete), IS 73 (Bitumen), IS 2386 (Aggregates)
Conclusion
This guide serves as a comprehensive framework for highway/expressway engineers, project managers, and field engineers, providing essential knowledge in contract administration, quality control, and project execution as per IRC SP-84 and EPC guidelines.