WELCOME TO TRAINING PROGRAMME FOR CONSULTANTS’ SERVICES FOR 3 rd PARTY QUALITY CONTROL AND QUALITY ASSURANCE G. PRABHAKAR

CHAPTER 1

Quality PlanningQuality ControlQuality AssuranceQuality Audit and Quality Improvement  Design  Drawings  Specifications  Staff  Training  Laboratories  Site Organization  Debris disposal  testing of Materials at source  Borrow areas  Mix designs  Quality Control Manual  Pre Construction Activities  During Construction Activities  After construction Activities and curing  Inspections  Sampling  Testing  Reporting  Control charts  Documentation soft & Hard copies  Photographs records  Video film records.  Scrutiny of Reports and tests data  Improvements required QUALITY MANAGEMENT SYSTEM

QUALITY ASSURED BY

PARTIES INVOLVED IN THE WORK TO ENSURE QUALITY  PARTY – I: Project Engineers  PARTY – II: Construction Agency  PARTY – III: Quality Assurance Consultants

CONTRACTOR AND PROJECT ENGINEERS PROJECT ENGINEERS:  are primarily responsible for Quality Assurance of the work being executed and to conduct all field tests before allowing further work. Shall check and produce to inspecting officers the following records and O.K. Cards maintained by the Construction Agency.

a) Registers:- 1.Site order. 2.Register of Bench Marks 3.Material O.K. Register. 4.Register of foundations. 5.Register of placement for concrete, Embankment, Reinforcement and other test reports. 6.Register of test reports of compressive strength of concrete specimens. 7. Cement day Book. 8. Register for embankment placement 9. Roller press control register 10. Moisture Control Register 11. Embankment test results register 12. Register for shot crete 13. Register for Aggregate testing

b) O.K. Cards for Big Structures and Heavy Embankments: 1.O.K. card for cast-in-situ concrete lining. 2.O.K. card for Earthwork Embankment 3.O.K. card for grouting 4.O.K. card for structural concrete work. 5.O.K. card for sub-grade preparation. 6.O.K. card for RR Masonry 7.O.K. card for shot creting 8.O.K. card for grouting

 AE/AEEs have to check pre levels and final levels.  For measurements recorded by Construction Agency, D.E.Es to test check measurements spread over the entire work. E.Es/S.Es to check measure as per Codal provisions and rules in vogue.  The measurement records have to be maintained by Construction Agency and finally handed over to the Engineer-in-Charge.

 The observations made by Third Party Quality Control, Department Quality Control Staff have to be invariably complied with before the next bill for payment is presented. To this effect certificate has to be recorded by Construction Agency and countersigned by the field engineers.

 It will be better if the Monthly review meetings are conducted by the concerned SE’s invariably involving Quality Control and construction agencies to discuss the Quality Assurance aspects and record the minutes of the said meetings.

QUALITY CONTROL STAFF  Shall verify the records maintained at site by the E.P.C. agency and the Third Party Quality Control Consultants.  The TPQC Consultant shall witness and verify 10% tests being carried out by contractor.  Shall associate with construction staff or conduct independently 10% tests with required frequency as per specifications.

QUALITY CONSULTANTS The Third Party Quality Assurance Consultants should posses all the testing independent testing to assure the Quality of work. Quality requirements should be clear and verifiable.

DESCRIPTION OF TASKS  Review of Design, plans and specifications for constructability and operability.  Important decisions regarding Quality of works are made during design and planning stages. Quality Assurance during construction depends on conformance to the design and specifications.

consultant to participate in designs review meeting with project engineers and contractor’s representatives and give suggestions, if any………………..

CONSULTANT TO PROVIDE Services enabling the Government to ensure best Quality of Construction in the Project by working closely with the Field Engineers. TASKS TO BE PERFORMED BY THIRD PARTY Review of Designs and Drawings HPs, Designs of Structures & Specifications and Review of QMP of EPC Agency.

 Review Contractor’s Test Data & Conduct tests in selected frequency.  Review of Mix Design  NDT Data on finished items  Non-Conformities – Corrective action  Calibration Report  Quality Certificate  Inter Lab Testing

CALIBRATION OF TESTING CEMENT QA consultant to verify calibration of all their and Contractor’s testing and measuring equipment – reports on calibration status, frequency of recalibration etc. to be submitted to the Engineer-in-Charge. The qualifications, experience of the testing personnel have to be assessed.

QUALITY MANAGEMENT SYSTEM  Quality of the work is dependent upon the participating constituents, some of which are sustainable and effectively controlled while others are not.  The process of managing the quality is through QMP.

QUALITY MEASURES  Periodic inspection, testing and verification.  Proper maintenance of records and registers.  Undertaking quality audit and review of QMP and QAP.  Provide training to all concerned.

STAGES FOR INSPECTION, TESTING AND VERIFICATION Input Materials Inspection. During Construction Inspection Completed work inspection.

Evaluate establish the contractor’s QMP (Quality Management Plan) requirements to see whether the Q.C organization possesses the following standards: 1) Evaluation of Testing and Inspection efficiency. - Effectiveness of procedures -Operation of Plant and Equipment -Adequacy of personnel and -Progress of records

2 ) Evaluation of Internal assessment: - Information that is adequate and accurate -Effectiveness of communication and feed back of Quality Control decisions to the operation level. -Control overall phases of operation. 3)Evaluation of overall performance of various Project Laboratories: -Procedures being followed -Performance of individual laboratories -Inter-Laboratory testing

COMPLIANCE Procedures and controls are of no significance unless meticulously followed. It shall be ascertained through. -Inspection and visual observation (Ex. Concrete lining in place, structural concrete in place etc and supplementing it by appropriate tests). -Examination of O.K. Card. -Persual of control charts for cement and concrete -Direct Enquiry.

VERIFICATION Consultant shall review the facilities and staff in labs. to determine whether -the personnel possess adequate knowledge of testing procedures and -the testing and inspections are adequate.

MONITORING CONTRACTORS PROCEDURES FOR TESTING DEFICIENCIES TO ASSURE CORRECTIVE ACTION TAKEN – QUALITY AUDIT  Construction Deficiencies and non-conformaties.  Report to the engineer to ensure that new work is not placed on unacceptable work.

LABS – TEST RESULTS Depend on -Competency of the testing personnel -Accuracy of the apparatus and equipment -Maintaining special environment conditions -Proper maintenance and periodical calibration of testing machines. -Lastly knowledge in interpretation of test results.

PRE CONSTRUCITON CHECKS INPUT MATERIALS Trained personnel with necessary equipment to verify for required specifications and the recommend for acceptance. Clear GUIDELINES to be drafted for inspection requirements, sample plans and acceptable quality levels. Test results and certificate of conformance to be furnished to Engineer-in-charge.

Corrective Action Notice to be issued by Consultant when material fails to conform to specifications. To inform the Engineer-in-Charge whether the material is passed or failed.

QA CHECKS – ON GOING WORKS To ensure the materials, construction works are as per specifications of APSS and IS codes. Defect prevention is preferred to detection after occurrence.

CONDUCT TESTS AT THE WORK SITE Consultants to maintain confidentiality as regards the sample testing. For reconciliation, the Engineer-in-Charge discusses with consultants and contractors. QA Consultant to organize inter-laboratory testing sample with NCCB and APERL for establishing the competence of project laboratories. This should be done once in THREE Months.

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