project quality plan (8.7.2012)

Project Quality Plan

Al Fowriya Trading & Contracting

Al Fowriya Trading & Contracting W.L.L.

P.O. Box: 24110, Doha-Qatar

Tel: 44425874 / 44212047, Fax: 44429027


Project: CONSTRUCTION OF NEW SECURITY GATE HOUSE AND

ADMINISTRATION BUILDING IN QP REFINERY AT MESAIEED

Client: M/s. Qatar Petroleum

Ref. No.

GC10109300/MS/001REV.0 Date: 09.06.12

Prepared By Checked By Approved By

QA/QC Engr FTC Project Manager FTC QP EDM



S No SECTION PAGE 01 Introduction 05 02 Project Scope 05 03 Project Quality Statement 06 04 Revision Status / Amendments 06 05 Definitions and Terminology 07 – 08 06 Quality Policy, Quality System & Quality Strategy

6.1 Quality Policy Concept 6.1.1 Quality Policy 6.1.2 Quality System 6.1.3 Structure of Quality management system documentation 6.1.4 Hierarchy of the documentation 6.1.5 Quality Management System manual 6.1.6 Quality Process & procedure manual 6.1.7 Project Quality Plan 6.1.8 Other Quality document 6.1.9 Quality Strategy 6.2 Planning 6.3 Control 6.4 Verifications

09 – 13

07 Quality Management in Construction and Reporting. 7.1 Management Responsibility 7.2 Organization set up for the Project 7.3 Job Responsibility matrix. 7.4 Responsibilities & Authorities 7.5 Functions of QA / QC system 7.6 Quality Management Reports 7.7 Management Reviews 7.8 Monthly Progress Report

14 – 23



08 Progress Control 8.1 Construction Work Program 8.2 Progress Control

24 – 25

09 Design Quality plan 9.1 Design Control 9.2 Control of Design changes 9.3 As Built Drawings

26 – 28

10 Quality Control and Assurance in Construction 10.1 Quality Control of Pavement Works 10.1.1 Methodology 10.1.3 Tolerances of Pavement Work 10.1.4 Inspection Test Plan 10.1.5 Checklist for Inspections 10.2 Measuring and Testing Techniques 10.3Handling and storage of Material 10.4 Identification of Non-conforming Product. 10.4.1 Site Notice / Non – Conformance Report (NCR) 10.4.2 Correction, Corrective Action and Preventive Action.

29 – 83

11 Documents Records and Control 84 – 85

12 Internal Quality Audit 86 – 87 13 Training in Quality Assurance 87 – 87

14 List of Tables 13.1 List of Materials Tested on site 13.2 List of Materials to be obtained Manufacturer’sCertificate 13.3 List of Test and Procedures to be conducted at Site.

88 –94

Appendices A1 Test Report Format A2 Inspection Test Plan A3 Inspection Checklists Department name: Project operation

5 of 94



1.0 Introduction:

The Globalisation and developing Technology in the Construction Industry is

leading to High competition in the Current market. The best response to a

competitive challenge in the Construction Industry is to become more

competitive. The best means of achieving this is by improving the product quality

and meeting the project schedule through a well designed Quality Management

system. The Quality Management system shall focus on providing improved

control on processes and practices, thus enhancing customer satisfaction

through its effective implementation

2.0 Project Scope:

Contract Number : GC10109300

QP Project Number : 3391

Project Start : 27th February 2012.

Mile Stone 1 (Construction Completed) : 26th August 2013.

Mile 2 (Testing, commissioning : 26th February 2014.

& Handover – Project Finish)

Construction of the new security gate House and Proposed facility as

Mentioned below, including procurement, installation, pre-commissioning,

Commissioning and testing.

Scope:

Single storied Gatehouse to replace the existing Gatehouse.

A two-storied Security Building with offices for security staff and full height

turnstiles for control of pedestrian traffic.

Shaded parking for security staff cars.

Safe set-down/pick-up bay for two (2) buses.



Demolition and modification of asphalt paved roads, with necessary

Markings and sign boards, including construction of new round about at, new

refinery administration complex access road intersection.

Extension of existing pipeline / utility culverts.

Entrance/exit road barriers and pop-up blockers for vehicular traffic Control.

Bollards for protection of buildings.

Demolition and modification of existing boundary wall.

Heavy duty pre-cast block paving for new security staff car-park and the

Access to this car-park.

Hard landscaping around the buildings, new traffic islands, new round

about, sidewalks and modifications to existing paved areas.

Soft landscaping, to suit the road modifications, including relocation of

Existing trees.

Paved pedestrian walkway, with protection railing, from the bus bay

Extended beyond the new roundabout within the Refinery fence.

All services works, including tie-ins, pertaining to the above buildings and

Site development, including plumbing, drainage, fire-detection system, fire Management system and other specialist systems, equipments etc.

Security and Access Control system interfaced with Corporate Security Systems.

3.0 Project Quality Statement

To strive for Quality Excellence, in order to achieve Customer

Satisfaction by Providing goods and services to the standards set by the

customer and to contribute to increasing the Company’s competitiveness.

4.0 Revision Status / Amendments and Distribution

The issue number, revision number and revision date are

stated on each page of the Project Quality Manual. Should amendment of the

Project Quality Manual be necessary during the life of the project, only the

revised sub-section shall be reissued and its revision number and date changed



accordingly? Amendments shall be approved by the Head – Project Operations

at Head Office. The Revision Status Sheet detailing the amendment, date and

approval shall be issued with each amendment by the Project Manager. Each

new revision shall be distributed as per the original with a request that the revised

sub-sections be destroyed. After ten (10) revisions a new issue shall be

introduced superseding all previous revisions. Registered copies of the Project

Quality Manual shall be distributed to the following:

5.0 Definitions & Terminology

Calibration All the operations for the purpose of determining the values of the errors of

measuring instruments, material measures, and measurement standards.

Controlled Document

An original numbered copy of a document for which amendments will be

Automatically advised.

Corrective Action

An activity the intention of which is to return a non-conforming item or action to a

Stat or conformity. It also covers action taken to prevent further recurrences of

Non-conformity.

Disposition

An action to be taken concerning material, components or products about which a

Decision has been made.

Document

Any written or printed manual, procedure or form that is part of the quality system.

The term includes documents and data that can be read by people or machines.



Inspection

The careful examination, measurement and testing of the characteristics of

Products and services to ensure they meet regulatory and contractual

requirements.

Inspection and test point

A location or stage in the manufacturing, production or construction cycle where

inspection and testing are performed by personnel whose responsibility is to

determine the acceptability of products or services and to record inspection and test

data.

Non-conformance / Nonconformity

A deficiency in characteristic, documentation, or procedure which renders the quality

of a product or service unacceptable or indeterminate or not according to specified

requirements.

Procedure

A document that specifies, as applicable, the purpose and scope of an activity; what shall be done and by whom; when, where and how it shall be done; what materials, equipment, and documentations shall be used; and how it is all controlled.

Product

Material, part, item, component, assembly, sub-assembly structure, plant equipment,

or finished project identified in or described in any standard or specification and

production or obtained as a result of some manufacturing or construction operation

or process.

Product Quality Audit

Inspection of the product at a lesser frequency than the inspection carried out for

normal quality control purposes as an aid to assessing the effectiveness of quality

control.



Quality Assurance

All those planned and systematic actions necessary to provide confidence that

products or services will satisfy given requirements.

Quality Audit

A systematic and independent examination to determine whether quality activities

and related results comply with planned arrangements and whether these

arrangements are implemented effectively and are suitable to achieve objective.

Quality System Audit

The independent examination of an organizations quality assurance system carried

out by an auditing team from within or outside the organization.

Quality Control

Those actions which provide a means to measure and regulate the characteristics of

a product or service to establish requirements. Operational techniques or activities

(e.g. inspection or test) used to verify technical and quality requirements for services

and or products.

Quality Policy

The overall quality intentions and directions of an organization as regards quality, as

formally expressed by top management

Quality Plan

A document setting out the specific quality practices, resources, activities and

responsibilities relevant to a particular contract or project.

Remedial Action

An action to be taken concerning material, components or products about which a

decision has been made.

Repair

The process of restoring a non conforming characteristic to a condition such that the

item conforms to the original specified requirements, where such a repair or

restoration is acceptable.



Verification

Confirming that an activity or condition conforms to specified requirement

6.0 Quality Policy, Quality System and Quality Strategy

6.1 Quality Policy Concept

The Quality Policy is communicated and made understood at all level of the organization through awareness program an display of the Quality Policy boards at all the Project sites/departments. The Quality Policy shall be reviewed annually for continual improvement and suitability to the purpose of the division. Taking Quality Policy as guide, the quality objectives are established in related functions and monitored in the monthly steering committee meetings and periodic Management Review meetings. Management review includes review of Quality objectives and specific policy statements with the view to achieve Quality objectives and meeting the requirements of the policy statement.

6.1.1 Quality Policy:

We aspire to fulfill the expectations of our customer by a dedicated and organized approach, which is amenable to skill and knowledge enhancement. We shall improve the competence of our Quality management System continually. Our focus to accomplish this aim shall be on:

Effective design

Effective Implementation of planning and Methodology

Effective Supplier Management

Proficient Management of Workforce.

Training and development of Human Resource.

6.1.2 Quality System.

The Quality System has been designed to ensure that the Quality Policy, objectives and the requirements of ISO 9001:2008 are implemented. The system has been determined in terms of the following main processes.

Estimation, Costing and Tendering

Design and Engineering

Quality planning and Control

QUALITY POLICY

Quality management manual

Quality process and procedure manualOther quality documents (standards, Records, Guidelines Checklist etc...




Planning, Monitoring and Control

Plant and Machinery provision

Project Operation

Commercial, Contract and Procurement

Personnel and training

Finance

Quality System

6.1.3 Structure of Quality management System documentation

6.1.5 Quality Management System Manual:

This quality Management system manual describes the purpose

and scope of the Quality management system. Interaction of functional process and

establishment of documented to fulfil requirements of ISO 9001:2008 standard. The

applicable causes of ISO 9001:2008 standard have been included in the chapters

describing the systems as applicable.

6.1.6 Quality Process and Procedure manual:



The Procedures are established to meet the requirements of ISO

9001:2008 and are included in the quality process and procedure Manual. These

procedures covers control of documents, control of records, internal quality audit,

control of non conforming products and corrective / preventative actions.

6.1.7 Project Quality plan:

A definite quality plan for every project, detailing there in the

activities, Acceptance criteria, Verifying documents, controlling agency

(Organization/Customer) and the type of control and responsibility for implementing

the activity and its control, including resource requirements are developed before

start of the Project.

6.1.8 Other Quality Documents:

Quality records and formats from this level of documents. Other

standards, check list and guidelines are also used for the supports of overall quality

system structure.

6.1.9 Quality Strategy:

Implementation of the quality Management system and its

effectiveness is ascertained by periodical monitoring as well as by structured internal

quality audit and corrective and preventive action to ensure improvement in

effectiveness of the Quality system in operation. A continuous process of feasible

Technology up gradation and value analysis is initially targeted at persisting un

solved non-conformities to be attended to as well as potential problems.

Management review of the quality system is conducted periodically, to check for

continued suitability for effectiveness, towards meeting the requirement of the

organization’s Quality Policy and objectives. The integrity of Quality Management

System is ensured when changes are planned and implemented.

6.2 Planning



This Project Quality Manual is the document which details the Quality System to be planned, established, implemented and maintained as part of the contract for the road works for the project The Project Quality Plan consists of the following: (i) The Project Quality Statement of the company

(ii) Project Specific Details including Organization and System Element Description.

(iii) Inspection and Test Plans (including Construction Process Flowcharts and Quality Verification Checklists).

(iv) Project specific Procedures as required by the contract specification / concession agreement The Project Quality Manual describes the managerial and technical systems which shall be implemented to achieve conformance to specified requirements. The systems shall cover on site work under the contract. Where necessary the systems shall be extended to include offsite activities. The inspection and test plan shall identify necessary inspections and tests to verify conformance of the work during performance of the identified project tasks. It shall include acceptance criteria and details for performance of inspection and test activities, as applicable. 6.3 Control Control shall be achieved by implementing the requirements of the Project Quality Manual including construction process controls, inspection and test plan and audit requirements. Continuous monitoring and the investigation of timely corrective action shall form the basis of control. System Element Descriptions shall detail the methods by which the quality system is controlled. The agreed Inspection and Test Plans shall be used for controlling the work and detecting non-conformance. 6.4 Verification Verification processes shall be established to ensure that the planning and controls have been effective and the Quality System and constructed works conform to the specified requirements. The outcome of all verification activities shall be documented and maintained as quality records. Records of conformance shall be available for inspection by the Client / Client’s Representative upon request to provide evidence of the outcome of activities undertaken to achieve conformance. 7.0 Quality Management in Construction and Reporting 7.1 Management Responsibilities: The Head – Project Operations has the overall responsibility for construction of the

project, ensuring Customer satisfaction. The Chief Project Manager of Project will be

in charge of this Project and will be reporting to the Head – Project Operations.

Project Quality Plan will be implemented by the Chief Project Manager. The Project

QA/QC team will interact with QA /QC team of Client / Client’s Representative for

review of material tests, mix designs and QA/QC procedures as per the Project

Quality Plan and reports functionally to Head – QA/QC H.O. The Head – QA/QC H.O



will report to the top management and act independently to implements QA policy of

the Organisation. He has the responsibility for formulating, implementing, reviewing,

monitoring, verifying and assessing the effectiveness of Quality Assurance program.

He has also been delegated the authority to take corrective measures in case of any

significant quality related problems are noticed, with the intimation to the Chief

Project Manager.

7.4 Responsibilities of staff at Project Execution Team: 7.4.1 Project Manager the Project Manager for the project has the following responsibilities

Overall Management of this Project. He shall have the authority and responsibility for time, cost, and safety and quality aspects of the Project.

Determining the policy with respect to the management of quality on the project.

Issuing the Project Quality Plan including System Element Descriptions and Inspection and Test Plans.

Approving the disposition of Non-conformance Reports issued by the authorized representative nominated by him.

Communication and interface between CLIENT, Contractor, Subcontractors and the Project team.

7.4.2 Team Lead - Execution The Construction Manager for the project has the following responsibilities

Responsibilities for the planning, implementation, control and maintenance of the Project Quality Plan.

Issue all relevant documentation and amendments to the Project team.

Guide and instruct others in the essential aspects of quality management.

Verification of inspection and test activities.

Liaise with the contractor in regard of Final Inspection and Acceptance of the work.

Apply acceptance criteria and classify work as „conforming‟ or „Non-conforming‟. Issue Non-conformance Reports where necessary.

Recommend remedial action and re inspect to close out.

Recommend corrective action in case of recurring non-conformance.



Communication and interface between CLIENT, Contractor, Subcontractors and the Project team

7.4.3 QA & QC Manager

The QA & QC Manager for the project has the following responsibilities. Responsibilities for the planning, implementation, control and maintenance of

the Project Quality Plan.

Guide and instruct others in the essential aspects of quality management.

Liaise that the quality of manufacture and construction satisfies the standards.

Ensure that suitable measuring and testing equipment is available and calibration of same is monitored regularly.

Verification of inspection and test activities.

Recommend remedial action and re inspect to close out.

Recommend corrective action in case of recurring non-conformance.

Responsible for preparing Monthly Quality Management Report

Interaction with CLIENT‟s representative, approval of all materials as per CA in day to day basis.

7.4.4 Execution Engineer

The Execution Engineer has the following responsibilities. o Assist Project Manager in all aspect of Project Management.

o Responsible for overall execution of all aspect of Pavement as per working drawing and inspection of works on site as per Contract agreement, Specifications and Project Quality Plan.

o Monitor and Guide the Project Team in aspect of Project Progress, Quality and Safety.

o Recommend corrective action in case of recurring non-conformance.

o Responsible for Participating in preparation of Monthly Progress Report.

o Interaction with CLIENT all aspect of works.

7.4.5 Safety Manger The Safety Manger of the project has the following responsibilities. o Assist Project Manager in all aspect of Safety and Environment Management compliance as per Contract Agreement.



o Responsible for overall implementation of Safety and Environmental Compliance plan.

o Monitor, Inspect and Guide the project team in aspect of Safety, Environmental Compliance w.r.t Contract agreement.

o Carry out regular inspection in line with the requirement of contract agreement and recommend corrective action in case of recurring non-conformance.

o Responsible for participating in preparation of Monthly Progress Report.

o Interaction with CLIENT regarding all aspect of Safety and Environmental Compliance plan. 7.4.6 Planning Engineer & Quantity Surveyor

o Responsibilities for monitoring on day to basis the planned target and achievement. If any shortfall report to Project Manager, finding reason and make internal revised macro program to make up the shortfall.

o Responsible for preparation of Monthly Progress Report.

o Responsibilities for maintaining all documentation related to progress, verification of quantity in B.O.Q.

o Generating all compliance report required to be submitted.

7.4.7 Lab In charge

o Assist QA & QC Manager with the setting up of Field laboratories.

o He is the overall in- charge of testing, review and approval all material to be used for permanent works.

o Review and acceptance of quarry sites for aggregates , quarry spall , sand , borrow material Mix design for Concrete and pavement layers , and other bought out items to be used for the project.

o Supervise all the tests to be done in different stages of construction, besides ensuring that specified tests are done as per specifications, stipulated codes and Contract agreement.

o Maintain record of all materials at site and review the procurement schedule and assist the Project manager and Senior Material Engineer (SQME) in issuance instruction for correcting the same.

o Organizing independent tests other than the regular tests done by laboratory personnel.



o Verify manufacture test certificate and ensure quality control testing of all materials and completed works are as per the technical specifications.

7.4.8 Surveyor o Report day to day basis to Construction Manager in all aspects of Survey work.

o Responsible for organizing for detailed survey for the Pavement, checking alignment, Horizontal and vertical profile, Cross section w.r.t to the designed profile. Any difference shall be reported to Construction.

o Preparation of Cross-section for execution.

o Checking Lines and levels for the execution of works in accordance with drawing and Contract Agreement. 7.5 Functions of QA / QC System: i) For each major activity of work, method

statement will be prepared indicating the quality checks for incorporated materials

and stage of construction. Detailed description shall be followed in later part of this

section 10. ii) Ensure that equipment and testing instruments are calibrated properly

and adjusted to maintain their accuracy within acceptable limits. iii) Provide day to

day routine checks on materials and finished products. iv) Identify problems and

initiate action, which results in solution. v) Verify implementation of solutions /

corrections.

vi) Report regularly on effectiveness of the system. vii) Tests to be performed jointly

with Contractor and CLIENT at site before start of any activity and after review /

approval of the same activity have to start. viii) All the test reports have to be certified

by the Contractor and CLIENT‟s Representative. CLIENT has to nominate his

representative‟s for joint testing during site working hours. In case of non availability

of CLIENT‟s Representative, tests will be carried out by Contractor‟s QC Engineer

under information in the interest of work. ix) All records of qualifying and routine tests

/ checks will be jointly maintained at the QA/QC MANAGER‟s office. x) Monthly

Project QA report will be prepared by project QA/QC MANAGER, summarizing the

activities of QA department which is to be submitted to Management. xi) Head of QA

from H.Q shall deploy his representative to carry out internal quality audit to ensure

compliance of quality measures covered hereunder and to make necessary

improvement, if required in quality system. xii) Project Manager / QA & QC In-charge

through his representative at site will point out the non-conformity of standards if any,



to the contractor‟s authorized representative in writing and a copy of the same to be

sent to the General Manager for getting the work done as per quality standard

required as specified in Contract Agreement, quality specifications or drawings.

CLIENT, Contractor, Sub contractors, Material supplier and Manufacturer, each form

a link of the quality chain. The strength of this chain is dependent on each and every

link. The QA/QC MANAGER is to keep a continuous watch on this chain and spot

the weak link before it snapped.

7.6 Quality Management Reports: The QA/QC in-charge at site shall prepare a

Monthly Quality Management Report for review by the Project Manager /

Construction Manager. The Quality Report shall be subdivided into the following

headings: Summary of Inspection and Test Activities. (Field & Laboratory) Registers

of Non-conformance & Corrective Action. Status of Approvals of all Materials.

Outstanding approvals by the CLIENT‟s Representative Items of specific concern.

General Notes The Quality Management Report shall be submitted to the Project

Manager within one week of the close of the monthly reporting period and in turn Site

shall forward this to Head Office (QA) within 5th of every month for record and

distribution to the respective section in charge for record and action required if any.

7.7 Management Reviews: The operation and effectiveness of the Project Quality

Plan shall be regularly reviewed by Management Review meetings held once in Two

months for the duration of the project. The monthly Quality Management Report

together with Audit Reports shall form the basis of the review. The Management

Review meetings will be attended by the CEO, Head – Project Operations,

Management Representative, and Project Management team. Minutes of the

management review meeting will be taken by the MR. He shall be responsible to

prepare and distribute minutes to the members of the review Committee for their

information and action.

7.8 Monthly Progress Reports: The Monthly progress report shall be prepared at

site and submitted to the CLIENT as per requirement of Contractor agreement. The

detailed format for the report, contained all the activities of the month, major



achievements, miles stone achieved, progress, quality control reports, problems,

issues etc.

8.0 Progress Control This section of the Manual outlines requirements and procedures for construction scheduling and control of work progress. 8.1 Construction Work Program The Contractor is required to submit a detailed work program for execution of the works as per the QMS Process S00/PO/P/03 – Project Planning & Budgeting process – site. This program must show the following, as a minimum: Itemized work activities to be executed, based on the Contract‟s Bill of Quantities, indicating start and finish dates and scheduled achievement (progress) each month;

Sequencing of work and activity interdependence;

Calendar day estimates for submittal approvals; and

Calendar dates for achievement of various milestones, and for completion of works by section and of the project as a whole, within the time periods provided for in the Contract.

The Contractor‟s program should show the critical path activities, and the float

available for activities outside the critical path. It should preferably be prepared

based on a commercially available project scheduling software package, such as

Microsoft Project / Primavera. The Contractor should also furnish a breakdown of his

anticipated monthly earnings for payments in accordance with the terms and

conditions set forth in the Contract. Based on work program, Contractor shall review

and submit it to the CLIENT as stipulated in the Contractor agreement for his review

and approval. Once approved, the program cannot be modified except with the prior

approval of the CLIENT‟s Representative. The CLIENT approval of the program

does not relieve the Contractor of his obligation to complete the works or sections of

work within the time periods stipulated in the Contract Agreement.

8.2 Progress control The Contractor is required to undertake its activities in accordance with the approved work program. Each month the contractor shall indicate the actual work completed as compared to work scheduled as per the QMS Process S00/PO/P/04 – Project Monitoring Process – site. In the event portions of the work are in danger of being delayed, or actually are delayed, the contractor is to determine a plan for remedial action. Various circumstances may justify the changing of contract requirements for completion of the project on a specific date. Among these circumstances are items not within the control of the Contractor, such as: changes to contract requirements



(modification of Contract); suspensions of work; delays in providing access; force majure, etc. Generally, such occurrences will justify a delay in completion if they affect activities on the critical path of the program. However, each instance must be carefully evaluated and fully documented before a decision can be made. The following are guidelines for controlling work progress: There should always be a baseline program. If changes to the baseline program are required, an updated baseline program (baseline program no. 2, etc.) should be created.

Unauthorized changes to completion milestones should not be allowed, unless authorized by a contract modification.

Contractor shall monitor the progress of works and should update their completion percentages and report to CLIENT through Monthly Progress Report.

When actual progress falls behind scheduled progress or when it appears that a milestone will not be completed on time, the Contractor must identify the reasons for delay and in conjunction with CLIENT the Contractor make recommendations for remedial actions. 9.0 Design Quality Plan The Contractor shall engage a Design Consultant for the

preparation of detailed designs and drawings as per the QMS Process S00/DE/P/01

– Design Consultants Registration and Pre qualification process &

S00/DE/P/02 – Design Consultants Final Selection Process. The Contractor‟s

Design Consultant shall submit the designs and drawings to the Contractor and the

Contractor‟s Design Review Team shall review and check these designs and

drawings before they are forwarded to CLIENT for their comments and approval.

9.1 Design Control This section of the PQP outlines the requirements for the control

and management of the designs which are prepared by the Design Consultant as

per QMS process S00/DE/P03 – Design Management Process. All designs and

drawings, including design calculations, shall be prepared by the Contractor‟s

Design Consultant, based on the Employer‟s Requirements in the Contract and in

accordance with applicable design standards and criteria, codes, and methodology.

The drawings shall basically show details of the Works and, where applicable, their

sequence of construction. Prior to carrying out any designs, the Contractor and the

Design Consultant shall arrange to procure all the survey and site data such as

pavement evaluation. Data provided by the Employer as part of the Tender

Documents shall be verified through confirmatory survey and investigations. The



Design Consultant shall also prepare a Design Brief listing out all the design criteria

to be adopted for the designs of the Works. This shall be checked by the

Contractor‟s Design review team and if in order, this shall be submitted to the

Employer for their comments and concurrence. This Design Brief shall then form the

basis of all designs and drawings of the Works. Drawings shall generally be

prepared by computer aided design methods.

The flow of design documents shall generally be as follows:- a) The Design Consultant shall prepare all designs and documents and have them internally checked as per their own design quality control plan. All designs and drawings shall be signed and dated by the Design Consultant‟s draftsman, designer and the design checker.

b) These documents shall then be submitted to the Contractor. The Contractor‟s Design Review team shall check the drawings and calculations for completeness, correctness, legibility and conformance to the contractual requirements.

c) These designs and drawings shall then be submitted to the Employer in such number and format as stated in the Contract for their review, comment and approval.

d) The Employer or the Employer‟s Representative shall review and comment on the Contractor‟s designs and drawings. Regular meetings shall be arranged between the Employer‟s Representative, Contractor and Design Consultant in order to expedite the process of review and concurrence of the designs and drawings.

e) The Employer‟s Representative shall signify “no comment” or “comments made” or “resubmit” and return one copy of the designs and drawings to the Contractor.

f) The notes “no comment” or “comments made” will enable the Contractor to proceed with the construction of the relevant works. The Contractor shall issue these drawings to the sub-contractor for construction.

g) Where the designs and drawings are marked “resubmit”, then such documents shall be amended, modified or prepared again and resubmitted to the Employer. The process as mentioned above shall be repeated until the Employer‟s Representative signifies “no comment” or “comments made” on these documents.

h) The Contractor shall maintain a detailed register of all designs and drawings and the status of their submissions and review by the Employer.

9.2 Control of Design Changes This section of the PQP outlines the requirements

for the control and management of the designs Changes as per QMS process

S00/DE/P03 – Design Change Management Process.



The Contractor may initiate design changes due to site conditions being different

from that envisaged during preparation of the initial designs, or for other reasons.

The Employer‟s Representative may also order changes as provided for under the

Contract. The Contractor shall provide Design Consultant with all the necessary

instructions and site information, and the Design Consultant shall prepare the design

changes, together with the design change report, where applicable. The process for

submission, checking and concurrence the design changes by the Design

Consultant, the Contractor‟s Design Review team and the Employer‟s

Representative shall be the same as set out for designs and drawings under item 9.1

above. The Contractor shall keep the sub-contractors informed of any imminent

design changes and shall issue the revised drawings to the sub-contractor for

construction for construction soon after the drawings are concurred by the

Employer‟s Representative. The Contractor shall update the design and drawing

register for the design changes made.

9.3 As-Built Drawings The Contractor is responsible for the preparation and

submission of „as-built‟ drawings once the Works are constructed and completed.

During the course of the construction works, the Contractor shall maintain a

complete set of the latest „construction drawings‟ marked up with the as-built details.

The as-built details shall be updated on a regular basis until the whole of the Works

are completed. Where revised drawings have been issued to incorporate design

changes, the as-built details shall be transferred and marked up on the revised

drawings. Upon completion of the Works, the Contractor shall prepare as-built

drawings incorporating all the as-built data collected and submit the as-built drawings

to the Employer‟s Representative in the format and number as specified in the

Contract and as required by the Employer‟s Representative. The Employer‟s

Representative shall review these as-built drawings and after reviewing, shall

endorse them as reflecting the as-built details of the Works.

10.0 Quality Control and Assurance in Construction 10.1 Quality Control of

Pavement Works: QA/QC Performing required Mix designing Reject the Source Mix

design approved by Client Getting approval For Mix Design from Client Flow Chart



for Quality Control At Site Responsibility Identification of Source for material RFI for

Sampling and testing Joint Sampling and testing with Client Source approved by

Client N Y N Registering and Use for Construction Y RFI for Work to be excuted

Joint Inspection with Client Conducting necessary field and laboratory testing Work

Approved by Client Start next stage of work Y Non Conformance by Client N Repair /

Removal / Demolish as per instruction by Client Rework

10.0 Quality Control and Assurance in Construction 10.1 Quality Control of

Pavement Works: QA/QC Performing required Mix designing Reject the Source Mix

design approved by Client Getting approval For Mix Design from Client Flow Chart

for Quality Control At Site Responsibility Identification of Source for material RFI for

Sampling and testing Joint Sampling and testing with Client Source approved by

Client N Y N Registering and Use for Construction Y RFI for Work to be excuted

Joint Inspection with Client Conducting necessary field and laboratory testing Work

Approved by Client Start next stage of work Y Non Conformance by Client N Repair /

Removal / Demolish as per instruction by Client Rework

CONSTRUCTION QUALITY CONTROL:

General: Quality control of materials forms an integral part of the overall construction and supervision function. Taken properly into account, it provides the link between the design and the finished works. Testing of construction materials is carried out for a variety of reasons and purposes including: Screening Tests (e.g. choosing a borrow source, an aggregate supplier, a manufacturer / supplier of cement etc.)

Control Tests (e.g. sampling and testing of cement material delivered to site to confirm adherence to project specifications and to confirm manufacturer‟s Test Certificate)

Audit Tests to verify independently the reported properties of materials

Trial Mixes (selection of appropriate concrete mix designs, design of bituminous mixtures etc.)

Acceptance Tests (e.g. testing of cubes cast of produced concrete to confirm that required strength is achieved and is consistent)

Special testing as may be deemed necessary and prudent



Suppliers of manufactured materials such as cement, steel, bitumen, bearing pads,

Expansion Joints, Runway Furniture etc. shall be screened based on submissions,

review of sample Manufacturer’s Test Certificates and experience on previous

projects of the manufacturer. Independent testing by third party in the presence of

Contractor’s and CLIENT Representative may be carried out if required.

Control and approval of construction materials shall be based on the following: Test reports for materials tested , such as cement, sand, water, soil, aggregates and bitumen; and

Manufacturer’s certificates for materials such as steel, cement, admixtures etc.

The details of input materials should be recorded in a Materials Register (See

Format in Appendix A4).

All test results shall be entered into a test logbook / register maintained at site laboratory, with an indication of conformance/non-conformance. A format for test report log is given in Form in Appendix A4. This section hereinafter provides an overview of control requirements for materials, including site testing and manufacturers‟ certification. All materials to be incorporated and all works performed shall be strictly in conformity with the Contract agreement and specification requirements. Laboratory at locations shall be set up by the Contractor. The laboratory will be equipped with sufficient number of modern and efficient equipment suitable to carry out the tests prescribed for different materials and work according to the Contract agreement and specifications. The equipments shall be procured to conduct the specified test as per MORT&H and facilities to be provided. The laboratory will be manned by a qualified Material Engineer assisted by experienced Engineers, Technicians, Laboratory helpers and the set-up will be got approved by the CLIENT.

Test shall be carried out quality controls on the materials and work to the frequency described in subsequent paragraphs. In the absence of clear indications about method and or frequency of tests for any item, the direction of the CLIENT shall be followed.

For satisfying himself about the quality of the materials and work, quality control tests will also be conducted by the Contractor / CLIENT, generally to the frequency set forth herein under. Additional tests may also be conducted where in the opinion of the CLIENT need for such tests exist.



For the work of pavement, construction of subsequent layer of some or other material over the finished layer will be done after obtaining approval from the CLIENT. Similar approval from the CLIENT will be obtained in respect of all other items of works to proceeding with the next stage of construction.

Defective / Inferior quality of work shall be modified in the procedure of work, if found necessary, as directed by the CLIENT during inspection.

The Contract rate quoted for various items of works by the contractor in the Bill of Quantities or the lump sum amount tendered will be deemed to be inclusive of all costs of the quality control test and operations necessary for ensuring quality of the material and work so as to be in conformity with specification requirement.

All the tests to be conducted at laboratory and at site shall be documented as per the format specified in the later part of the section. Usually the documentation shall be maintained in such a fashion that it shall be very easy traceable with a specific RFI No. mentioned with date in layer chart for Pavement and in turn this shall be filed with bituminous and Non-bituminous in a separate file / volume as a lot with several sub lot. For all routine test for Pavements and other works, Borrow areas result, Bought out items shall be maintained in a separate lot irrespective of section.

10.1.1 Methodology:

SURVEY WORKS

1. Topographical Surveying

The Surveying actively is undertaken for the determination of control points and to afford sufficient data for the designing of engineering work such as site preparation and pavements. In the beginning of commencing works on any project, the following data shall be collected from Customer (Engineer / employer) or prepared by the Contractor. 1.1.1 Vertical Control Points (VCP) The records of all GPS Points carrying details shall be obtained from Customer (Engineer / employer). The data shall also include the Reduced Levels (RL‟s) of all TBM‟s fixed with location sketch and adjustment details from GPS to GPS. 1.1.2. Horizontal Control Points (HCP) The records of all GPS Points (X, Y) position and intermediate traverse points with location sketches shall be received from Customer (Engineer / employer). The data shall also include traverse carrying data and adjustment details from GPS to GPS Point. 1.1.1.3 Proposed Centerline Coordinates The co-ordinates (X, Y) for proposed centerline of the pavement. at a regular interval as specified by Customer (Engineer / employer) shall be obtained.



1.2. Survey works Survey actually in any project involves three stages of surveying necessary to be carried out at project sites. The survey work shall include

a) Preliminary Survey works:

Before starting the construction activity, Temporary Bench Marks (TBM), shall be established on the ground at specified interval. The control pillars shall be constructed before start of conformation survey for VCPs & HCPs. The pillars shall be constructed in staggered position within the project premises. The visibility between proceeding pillar to succeeding pillar shall be maintained. The control pillars are fixed at regular intervals of 250 or 200 meters. The TBM‟s shall be used as reference points for executing the works in the particular reach. The TBM‟s shall contain Reduced Levels of the ground and changing of that location. These shall beChecked periodically once in 3 months to ascertain the sanctity of levels. The levels shall be entered as per Rise & Fall for TBM Verification. The data shall be used for preparing site leveling & earthwork excavation plan, cross-section of the Pavement and working drawings. The centerline is also fixed for reference and execution.1.3 Survey work while execution Based on the reference of TBM along with reduced levels and centerline, each activity of the work during execution shall be carried out. 1.4 Survey work on completion of job After completion of work, Reduced Levels shall be taken up on the works, so as to ascertain the true levels as mentioned in the drawing are transferred to site. In case of any deviation, such changes shall be recorded and as built up drawing shall be prepared. 1.5 Confirmation of Survey works Immediately after receiving the survey data from the Customer (Engineer / employer), the Contractor shall confirm the survey data of the entire project. The confirmation process shall include the following aspects 1.5.1 Confirmation of Vertical Control Points The confirmation of Vertical Control Points (VCP) shall be undertaken by surveying from GPS to GPS points. The Rise and Fall method shall be adopted for TBM Confirmation Survey. The control pillars established shall be connected by this survey work. The TBM level after the survey work is recorded. 1.5.2 Confirmation of Horizontal Control Points The confirmation of Horizontal Control Points (HCP) shall be undertaken by surveying from a pair of GPS points to another pair of GPS Points. These values shall be checked with the values given by the Customer (Engineer / employer). The traverse points established shall be identified with nail punched on top of Pavement to get the exact point and shall be encircled with paint of golden yellow color.1.6 Transferring Survey Data to Control Pillars 1.6.1 HCPs to Pillars Once survey data of HCP is confirmed and control pillars are constructed, the coordinates (X, Y) shall be transferred from nails to control pillars by the Total Station. The transferring of levels and coordinates from nails to pillars shall be prepared.



1.6.2 VCPs to Pillars Once levels of TBM are confirmed and control pillars are constructed, the levels (Z Co-ordinates are transferred from permanent benchmark to pillar. The transferring of levels from permanent benchmark to Pillars shall be prepared. 1.7 Detailed Survey work for runways and Taxiways a) Setting out of proposed pavement centerline and construction of Reference Pillars shall be made after completion of confirmation survey works. Once the centerline is established, reference pillars shall be constructed on both sides of Runway. The centerline reference sheet containing data on reference pillars is given Centerline Reference Sheet.

b) OGL‟s are recorded before disturbing the existing ground level. Any construction activity i.e. clearing and grubbing etc. shall start only after taking OGL. In case of dense vegetation, removal of vegetation could start without disturbing ground level. OGLs are recorded in Field Book

1.8 Detailed Survey works for Structure Before setting out of centerline of new structures i.e. culverts and retaining head walls etc. site should be clean of all the logs, stamps and other deleterious matter, which may interrupt grid level. The contractor shall remove all water from waterlogged areas near Structures by suitable dewatering pumps. For controlling vertical and horizontal points for structural works, reference pillars are required to be constructed depending on type of structure. Separate pillars shall be constructed for VCP and HCP in structure location.

1.9 Instrument The work shall be carried out with Auto level instrument and Total

Station. The recent calibration report of the instruments shall be submitted and

approval shall be sought from the Customer (Engineer / employer) prior to the start

of levelling work in the field. The MS Plate shall be used for every change point to

support levelling staff, depending on the condition of the ground.

CLEARING, GRUBBING AND DISMANTLING STRUCTURES (Acceptance Criteria: Ref. Section 200 of MORT&H) 1. General This work shall consists of cutting, removing and disposing of all materials such as trees, bushes, shrubs, roots, grass, weeds, top organic soil not exceeding 150mm. Dismantling of structures acquired within ROW in brick work, stone masonry, plain/ reinforced concrete, timber structures, removing tiles, GCI sheets, etc., and sorting out dismantled materials, disposal of unserviceable materials and utilizing the serviceable materials at free of cost. 2. Procedure for clearing and grubbing: Original ground levels shall be recorded jointly before commencing C&G activities.



Before starting the Clearing and grubbing activity, information to the Client / Client„s Representative given.

Top-soil and deleterious material will be dozed and removed up-to 150mm thickness .All the dozed top soil will be removed from toe line and stacked /displayed away from the area of work.

All the trees, shrubs and roots will be removed from the stretch with the help of manpower / machineries.

Backfilling of the pits will be carried out if required with sand, saturated fully with water.

After completing the clearing and grubbing check-list will be complied.

3. Procedure for dismantling structures: Measurements shall be recorded jointly before dismantling of structure.

The structure shall be carefully dismantled and the resulting materials so removed shall not cause any damage to the serviceable materials and the structures nearby.

The connecting edges shall be cut, chipped and trimmed to the required lines and grades without weakening or damaging any part of the structure. Due care shall be taken to ensure that the reinforcement bars which are to be left in place so as to project into the new work as dowels or ties are not injured during removal of concrete while extending the existing culverts/ bridges. Equipment / Machinery Requirement: 1. Dozer

2. Excavator

3. Tippers

In dismantling pavements, MS pipes, guard rails, kerbs, gutter, and fencing, where

portions of existing construction are to be left in the finished work, the same shall be

removed to an existing joint or cut/chipped true to the lines with face perpendicular to

the existing structure.

project quality plan (8.7.2012)

Documents

security gate

environmental

qms process

internal quality

engineer employer

project quality

chief project

monthly progress