WELCOME TO

TRAINING PROGRAMME

FOR

CONSULTANTS’ SERVICES FOR 3rd PARTY

QUALITY CONTROL AND QUALITY

ASSURANCE G. PRABHAKAR

CHAPTER 1

Quality Planning Quality Control Quality Assurance Quality 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 BYQUALITY 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.

THANK YOU