Quality Control Plan

Rehabilitation and Upgrading of Pakpattan Canal,Khadir Branch and Pakpattan Islam Link Contract: PCSBIP/ICB-01

CONTENTS1INTRODUCTION21.1QUALITY POLICY21.2QUALITY OBJECTIVES21.3POLICY REVIEW31.4MANAGEMENT RESPONSIBILITY41.5QUALITY SYSTEM AT SITE62QUALITY ASSURANCE PLAN72.1CONTRACTORS SUBMITTALS82.2EARTHWORK122.3CONCRETE WORK152.4STONE PITCHING & STONE APRON182.5BRICKWORK163QUALITY CONTROL PLAN183.1PREFACE183.2DOCUMENT CONTROL183.3PROCUREMENT CONTROL193.4CONSTRUCTION MATERIAL CONTROL203.5PROJECT PROCESSES213.6CALIBRATION OF VARIOUS DEVICES / EQUIPMENT243.7TEST PROGRAMME243.8QUALITY RECORDS303.9TRAINING333.10INTERNAL QUALITY AUDITS34

INTRODUCTIONThe Punjab Irrigated Agriculture Investment Program (PIAIP) is being financed jointly by the Asian Development Bank (ADB) and the Government of Punjab. The Investment Component of PIAIP includes Rehabilitation and Upgrading (R&U) of Pakpattan Canal, Khadir Branch and Pakpattan Islam Link. After a Process of International Contract Bidding (ICB), the contract is awarded to M/s Sinohydro NEL Joint Venture on the basis of fulfilling the international standards of expertise in construction. QUALITY POLICYIt is the policy of SINOHYDRO-NEL Joint Venture, to supply work and services of high and consistent quality to its Clients. These will be in accordance with the SINOHYDRO-NEL Joint Venture organisational goals, Clients requirements and expectations. This policy will be reviewed at regular intervals to ensure that it is still up to date and relevant.

All operations shall be carried as per Standard Operating Procedures or Technical Specifications provided by the client. Deviation from the procedures and specifications must be first notified to the Management. Management is responsible for final approval of all changes to procedures prior to implementation.

It is part of the SINOHYDRO-NEL Joint Venture training programme that this policy is understood, implemented and maintained at all levels in the organisation. This statement represents our commitment, on behalf of SINOHYDRO-NEL Joint Venture to the Quality Policy.

Responsibilities Project Manager is responsible to implement this policy at site.

QUALITY OBJECTIVES Following are the Quality objectives based on the SINOHYDRO-NEL Joint Venture Quality Policy;

Adherence to work schedules on time, each time. To propagate the company Quality Assurance and Safety policy objectives at site.

Ensure the highest level of quality by maintaining supervised controls and written instructions governing Quality Control procedures & practices. Establish clearly defined responsibilities for compliance. Meet contractual requirements by conformance to Contract Documents and applicable standards. Complete & maintain accurate records of inspections and tests. Ensure that corrective action is properly implemented and documented. Maintain procedures to ensure that quality requirements are communicated to all levels, including sub-contractors. Provide healthy working and living environment at site and ensure our Safety targets of Zero Accident, Zero Injury and Zero Property Damage. Enhance working skills of personnel through formal on-the-job and planned training.

The Quality policy and Objectives are to be circulated to all departments and section In-charges at site, who will be responsible for its understanding, promulgation and implementation. The Quality Policy is to be displayed at all the prominent places to facilitate maximum exposure to the SINOHYDRO-NEL Joint Venture employees.POLICY REVIEWPolicy Review responsibility at site is through a review committee consisting of PM and In-charge of the sections. This review committee is to periodically coordinate and control the activities of the Quality System being carried out at site, review and evaluate the performance of the Quality System and attainment of Quality objectives. The maximum period between Policy Review meetings is two months. However, the meeting may be called at any time when it is considered necessary on the direction of PM.The agenda of the Policy Review meeting is prepared by QA/QC Manager in consultation with the PM and distributed to the review committee well in time. The agenda covers but is not limited to the following points: The progress monitoring of execution activities. The organizational structure, including the adequacy of staffing and resources. The structure and degree of implementation of the Quality System. External / Internal Audit Reports. Discussions on the causes for non-conformities and verification of the resulting corrective / preventive actions. Customer complaints. Vendor / subcontractor Performance. Other Site Issues. Meeting Proceedings Meeting is to proceed in the following manner: Follow-up of the decision made in the previous meeting. If implementation is successfully achieved on previous decision, it is then eliminated from the agenda otherwise the reason for non-implementation is discussed and a remedial corrective action is decided. Point wise discussion as per Agenda. New points recorded with decisions on necessary actions and assigning of responsibilities for corrective and preventive actions against a target date. Record of the Meetings The minutes of the Policy Review meeting is to be recorded and distributed to all concerned persons for follow-up. The minutes include the name of persons who attended the meeting, matters reviewed, decisions taken on required actions, the names of persons responsible for implementing such actions and the dates by which they are to be completed.MANAGEMENT RESPONSIBILITYThe project specific organogram for site is placed at Annexure-AProject ManagerThe Project Manager together with his key functionaries have the declared responsibility for implementing the Quality programme in their respective areas of responsibility and operation. Brief Job Descriptions (JDs) is given below for the key functionaries at Site. He is responsible to prepare the Project Quality Plan and implementation of the project organization, execution, safety and quality plans. He keeps liaison between the Consultant, Client and Project team for overall directions. Plans construction programs and schedules for field execution operations in accordance with contractual requirements. Approves corrective and preventive actions on non-conformities.Site Manager He reports to the Project Manager for execution of production/construction, safety and quality plans in his area of execution. Helps in the preparation of Project Quality Plan in consultation with concerned departments. Controls & Supervises construction activities in his area of responsibility in accordance with contractual requirements. Co-ordinates with the field support groups, QA/QC and Safety for execution.

QA/QC Manager The Quality Control (QC) Manager will be responsible for overseeing overall implementation of Quality Control Plan and will coordinate all project testing, inspections and reporting matters directly with the Project Manager and Site Manager. The QC Manager and all workers have the authority to intercede directly and stop work due to any unsafe work practices or site conditions. Duties Preparation, approval and implementation of the QA&QC Plans. Verification of Material as per project Specifications. Inspection of delivered materials as per Project Specifications and Relevant standards. Co-ordination with Independent labs for conducting different test according to project specifications. Ensure that all materials and construction are in accordance with the requirements for the completeness, accuracy, constructability in compliance to the requirement of Contract Documents. Documentation for material and administrative approvals and backups. Carry out and participate in weekly progress and QC Meetings. Manpower adequacy checking as per scheduled activities. Supervision of Quality Inspectors for different Inspection activities. Inspection of Civil works executed by Sub-Contractors. Ensure to carry out all work in a safe manner in accordance with site rules and regulations. Carry out quality control checks as defined on quality plans as directed by Project Manager. Witness critical installation activities as defined on contractor's quality plan. Ensure that works are coordinated in an effective manner so that programmed objectives are achieved.

Construction ManagerConstruction Manager reports to Site Manager and is responsible to ensure accomplishment of field activities in accordance with approved Methodology & specified requirements. Manage construction field activities with the help of Site Engineer & supervisors. Co-ordinates with QA/QC for inspections, testing and identification of root causes against non-conformities.Planning EngineerPlanning Engineer reports to the Site Manager in his discipline and is responsible to schedule & detail planning of Resources against the specified scope of work. Monitor and Control progress maintaining & reporting. Preparation and approval of execution methodology from Consultant. Overall Control of Documentation flow to concerned sections. Co-ordination among concerned departments, sections, Consultant and Client for necessary arrangements and resources allocations.Manager AdminManager Admin reports to Site Manager and is responsible to establish and maintain administration system at site. Maintain personnel records, increments and pay allowances. Co-ordinates with labor and social security departments. Ensures arrangements of communication, transport, accommodation, messing, furniture and proper protocol for guests and visitors.HSE ManagerHSE Manager functionally reports to Head Safety and administratively to Site Manager and is responsible to implement the Project Environmental Management Plan, SSEMP, safety policy and Site HSE Plan. He is responsible to organize the Safety training program, ensure availability of P.P.E, fire-fighting equipment. Preparedness for accidents & crisis management.Resource Management All resource requirements at site are assessed on the basis of resource plans based on contract specifications. These resource plans are used for identifying, estimating, scheduling and allocating relevant resources. These plans are subject to multiple revisions, depending upon the actual usage requirements. For further details please refer to Project Process Control.

QUALITY SYSTEM AT SITE

PURPOSEThe purpose of the Quality System at site is to establish and maintain SINOHYDRO-NEL Joint Venture Consultant and Client specified Quality management system at Site.RESPONSIBILITYThe PM at site is responsible to establish and maintain the Quality System. SINOHYDRO-NEL Joint Venture Quality System is based on a hierarchy of the Quality Policy, QA / QC Plan, Specifications, Procedures & Methods, Analysis of Project Quality Records and Policy Review.

QUALITY ASSURANCE PLAN

This Quality Assurance Plan (QAP) is an effort to outline the activities of the SINOHYDRO-NEL Joint Venture in adequate details for the guidance of its staff and other relevant Personnel during the construction activities of the project to satisfy the requirements of Contract. It requires that individuals have clearly defined responsibilities and lines of communication to enable all aspects of the work activities to be assessed and accepted and if a problem is discovered, the solution is quickly found. QAP cannot replace the experience of reasonable and responsible staff; however it can help them in selection of timely and sequential line of various activities and in keeping and maintaining retrievable record documentation. This QAP is specially designed for Rehabilitation and Upgrading of Pakpattan Canal, Khadir Branch & Pakpattan Islam Link Project (Contract No. PCSBIP/ICB- 01).The SINOHYDRO-NEL Joint Venture is, in particular, responsible for the Quality Control of the Works as per Contract Specification. Consultants supervision and surveillance does not relieve the Contractor of his contractual obligations. The basic purpose of QAP is to ensure that the Quality Control System is in place and performing to the requirements of Contract documents during the construction period.The quality requirements are based on provisions for technical specifications as per contract documents for Rehabilitation and Upgrading of Pakpattan Canal, Khadir Branch & Pakpattan Islam Link Project. Maximum efforts have been exerted in making QAP an acceptable and tangible document for all levels of execution and supervisory staff and novice to experience. Technical notes are provided at places to develop field staffs approach and insight for a useful and effective supervision, without undermining adherence to the contract specification.The Contract Documents are the basis for this QAP, therefore, where an ambiguity is detected between the procedures and requirements of QAP and content of Contract Documents then the later takes the precedence.The following are the objectives while formulating QAP. To define and adopt a sequential and systematic quality assurance line of action with participation of the other stake holders for ensuring of all submittals, procurement, execution of works and other on and off site construction activities. These activities may also include material supply, testing and reporting envisaged in the specification of the project. To maintain auditable record of all tests, inspections, procedures and corrective measures and any other information considered helpful. To define the assignment and responsibilities of the Contractors field staff and other relevant personnel at site with respect to Quality Assurance of the project vis-a-vis the Contractors Quality Control Programme and their interaction with the client and the Consultant. To prevent non-conformities through proactive Quality Assurance.CONTRACTORS SUBMITTALSObjectiveThe objective of this Section is to guide the field staff of the SINOHYDRO-NEL Joint Venture regarding different submissions to be made in the form of check requests, test requests, approval requests and authorization requests for execution of work. These submissions will be made by for methodological construction execution works.ApplicabilityThe Contract Documents for Rehabilitation and Upgrading of Pakpattan Canal, Khadir Branch & Pakpattan Islam Link Project require the Contractor to submit certain documents to the Consultants, i.e. before, during and after the execution of the works. These documents / write-ups may include; Work Programmes (As per Contract specifications) Quality Control Test Results (As per Contract specifications) Drawings and data for Equipment (As per Contract specifications) Installation Instructions for Equipment (As per Contract specifications) Operation and Maintenance Manual for mechanical equipment (As per Contract specifications) Manufacturers Certificates for various Construction Materials like water stops, bearing pads, expansion joint fillers and sealants.

The submittals for various items of Project Works are provided in the checklist CKL-1.1 Checklist for Contractors Submittals for the guidance of the Contractors field staff.

CKL 1.1 (1) CHECKLIST FOR CONTRACTORS SUBMITTALS

General

Sr. No.SubmittalDocument FormatTime For Submission

1.1Contractors work Programme including arrangements, order and timingsContractors FormatAs per SpecificationWithin 28 days of delivery of LOA* and updates when required

1.2Details of the Programme and Resource ScheduleContractors FormatAs per SpecificationWithin 28 days of delivery of LOA

1.3Request for Survey check by the ContractorContractors FormatPrior to commencement of works

1.4Contractors Quality Control ProgrammeContractors FormatPrior to commencement of works

These submissions shall be made by the Contractor to The Engineer for prior detailed review and agreement/advice.* Letter of Acceptance.


Earthworks and Caring & Handling of Water


2.1Plan for Diversion Works*Contractors FormatPrior to Construction of diversion works

2.2Materials Source Approval*Contractors FormatPrior to commencement of component of work

2.3Quality Control/ Assurance Tests to be submitted direct to The EngineerContractors FormatAs per requirements of specifications and QAP

2.4SSEMP for Borrow Area.Contractors FormatPrior to start of Construction.

*These submissions shall be made by the Contractor to The Engineer for detailed review and agreement/advice.


Concrete Works


3.1Method StatementContractors FormatPrior to Construction

3.2Mill test Certificates for Steel ReinforcementManufacturers FormatAlong with delivery of steel at site

3.3Bar Bending ScheduleBB-013 days Prior to Commencement of fabrication of Re-Steel

3.4Quality Control Tests for Concrete worksRef. to section 3.7.As per requirements of specifications.

3.5Manufacturers Certificate for Rubber water stops, bearing pads joint filler and sealantsManufacturers FormatPrior to procurement

3.6SSEMP as per EMP requirementsContractors FormatPrior to start of Construction

These submissions shall be made by the Contractor to The Engineer for detailed review and agreement/advice.

EARTHWORKObjectiveObjective of this Section is to provide the recommended guidelines to the Sinohydro-NEL Joint Venture field staff for their guidance in performing quality assurance of earthwork for structures and for the canal embankments etc. pertaining to the Permanent WorksThis Section covers the open cut/foundation excavations, foundation backfills for the structures and earthwork for irrigation canal embankments. The recommended guidelines can also be used for other similar works and earthwork required for diversion arrangements.Construction EquipmentSelection of type of excavation and compaction equipment must be done wisely keeping in view the bulk of work and efficiency of the equipment and that the selected equipment is capable and adequate to perform the required earthwork. The following may be deployed as per the nature of work involved; Rehabilitation and Upgrading of Pakpattan Canal,Khadir Branch and Pakpattan Islam Link Contract: PCSBIP/ICB-01 Page | 1

Excavators Dozer Tractors with implements Front End Loaders Dragline Excavators / Cranes Dump Trucks Motor Graders Water Bowser Dewatering Arrangements Compactors(Rollers) Flood Light Arrangements

Inspection Setting out details on site as per design will be the responsibility of the field staff. The Consultants through their own field staff shall check the setting-out accuracy, survey control for NSL and design levels by joint survey with Contractor. These surveys shall be carried out by Contractors surveyors in the presence of Consultants Inspectors. The site inspector .shall monitor the excavation slopes for stability and compaction of the sub grade and fills, etc. If the Contractor encounters wet or slush, he is required to report to the Consultants Site Engineer who will jointly inspect the site, evaluate according to Earthwork Sub Clause of Technical Specifications of Contract Documents and submit their recommendations for approval by the Engineer. The Control of moisture and compaction of soils in the embankment of canals and compacted earth consists of inspection of the material used, checking the amount and uniformity of the soil moisture, maintaining the thickness of layer, and finally determining the percentage of relative Dry Density of the compacted fill. The relative Dry Density of the compacted fill is determined on the basis of Field Density Tests and the Reference Laboratory Compaction Tests. The Field Density Tests shall be performed by the Contractors staff as and when directed by the Engineer In-charge or Site Inspectors. Tests at critical areas shall be carrying out by Consultants staff and verified in Consultants Field Laboratory. The Standard/Modified Proctor Compaction Tests are used as Reference Laboratory Tests for fine grained clayey soils. These tests shall be performed at the Contractors Field Laboratory. The Maximum and Minimum Dry Density Test results (from external laboratory) are used as Reference Laboratory Tests for cohesion less sandy soils. The soils having less than 12% passing No. 200 sieve are defined as sandy or non-cohesive soils. The Site Inspector should see that all perishable matter and any soil which may become unstable upon saturation, such as highly organic soils, loose silts, very fine sands/silts and expansive clays etc. are not present in the foundations. These soils either need to be removed or improved to the extent necessary to provide a safe, stable foundation or sub-grade under operating conditions. A good bond between the foundation and first layer of fill is achieved by moistening the foundation rather than using a very wet embankment layer. For Quality Assurance (QA) of earthwork operations the Staff shall proceed in accordance with CKL-1.2(1) Checklist for Structural Excavations and CKL-1.2(2) Checklist for Canal Earthworks. An important function of inspection is to determine when and where to make Field Density Tests. These tests should be made in areas where degree of compaction is doubtful. Areas of doubtful density are sometimes detected by observation. Possible locations of insufficient compaction include: The junction between areas of mechanical tamping and rolled earth fill embankment along abutments or cut-off walls. Areas where rollers turn during rolling operations. Areas where too thick layer is being compacted. Areas where improper moisture content exists in the soil. Areas where less than specified number of roller passes were made. Areas where oversized rock which has been overlooked, is contained in the fill. Areas containing material differing substantially from the average.

Specified Limits for Degree of CompactionWhile performing control over compaction the limits given below from specifications should be observed.Compaction Requirements

DescriptionCohesive SoilsCohesionless Soils

Backfill around Structures above foundation level90% Modified Proctor Dry Density70% Relative Density

Special Backfill and Fill beneath Structures (Foundations)95% Modified Proctor Dry Density80% Relative Density

Foundation under Canal Embankment / Sub-grade for Lining 90% Modified Proctor Dry Density70% Relative Density

Canal Embankments(Main or Branch)90% Modified Proctor Dry Density70% Relative Density

Disty/Minor embankments90% Modified Proctor Dry Density 70% Relative Density

Frequency of Control TestsThe recommended tests, their procedures, frequency and the required facilities for an effective quality control/assurance of earthwork are presented in Section 3.7 Test Programme. The contractors field staff is required to ensure that these tests are performed as per specified frequencies in the recommended laboratories or at site. The field tests should be performed in the presence of the Engineers site Inspector and the results recorded immediately on completion of the test, duly signed by the authorized representative of the Contractor and Consultants. An independent record of the tests should also be maintained by consultants field staff, in addition to the submittals of the Contractor.CKL 1.2 (1) CHECKLIST FOR STRUCTURAL EXCAVATIONS

Sr. No.IssuesAction byRecord/Reporting Document

1. Level of TBMs established by the Contractor, Confirm by Survey Control.

Engineers Rep.

Contractors Surveyor

Survey & Level Book and Ref. to Section 3.7

2. NSL by checking of the survey data and record entries. Check and approve by Survey Control.

3. Complete setting out/layout. Check by Survey Control and Dimensional Inspection.

4. Location and level of level pegs, Check by visual inspection and Survey Control.

5. Location of spoil or dump for excavated material. Optional Check by Visual Inspection.Lab TechnicianRef. Section 3.7

6. Deployment of proper Equipment. Lab TechnicianRef. Section 3.7

7. Adequate dewatering to desired levels, before start of excavation below water table. Water level to be maintained 3 ft. below the lowest foundation level. Ensure by physical inspectionLab TechnicianRef. Section 3.7

8. Complete information about condition of soil i.e. dry, wet or slush. Check by physical inspection and record observations.Lab TechnicianRef. Section 3.7

9. Stability of excavated slopes. Ensure by physical inspection.Lab TechnicianRef. Section 3.7

10. Final levels of excavated surfaces and record entries. Check by Survey Control and make record entries.Engineers Rep.Contractors SurveyorSurvey & Level Book and Ref. Section 3.7

All actions should be taken in accordance with the Contract Specifications and Contractors Work Methodology as approved by the Engineer.

CKL 1.2 (2) CHECKLIST FOR CANAL EARTHWORKS


1. Level of TBMs established by the Contractor to be checked jointly.

-Engineers Rep.-Contractors Surveyor

Survey & Level Book and Ref. to Section 3.7

2. NSL by checking of the survey data and make record entries by Joint Survey.

3. Complete setting out/layout. Check by Survey Control and Dimensional Inspection.

4. Location and level of level pegs, Check by spot visual inspection and Survey Control.

5. Final levels of excavated surfaces. Check by Survey Control.

6. Deployment of proper equipment. Lab TechnicianRef. Section 3.7

7. Clearing, Grubbing and Stripping. Ensure by physical inspection.Lab TechnicianRef. Section 3.7

8. Approval of backfill material (excavated or borrowed). Check by physical Inspection or Test Procedures.Lab Technician Field Lab.Ref. Section 3.7

9. Compaction control during execution Check by physical Inspection and Test Procedures.Lab TechnicianRef. Section 3.7

10. Records of all Tests made during time period. Update periodically.Lab TechnicianRef. Section 3.7

All actions should be taken in accordance with the Contract Specifications and Contractors Work Methodology as approved by the Engineer.

CONCRETE WORKObjectiveObjective of this section is to provide the recommended guidelines, sequential inspection procedures and other relevant information to the field staff of the Contractor for their guidance in quality assurance of reinforced concrete and pre-stressed concrete pertaining to the permanent works being executed at site. ApplicabilityThis section covers Plain Cement Concrete (P.C.C.), Reinforced Cement Concrete (R.C.C.) and pre-stressed concrete works for permanent structures as well as pre-cast works as shown on the drawings and as directed by The Engineer.Construction EquipmentThe Contractor must ensure that the equipment is adequate to perform the concrete work.Inspection1) For quality assurance of construction activities the Consultants Supervisory Staff shall proceed in accordance with CKL-1.3 (1) Checklist for concrete work.2) For effective Quality Control, the Contractor is required to perform certain tests at different stages of the concreting process. These tests include tests to be performed on concrete ingredients, before start of the concreting works, tests to be performed during construction stages and the tests to be performed subsequently in the Contractors Field Lab. or in any other approved external laboratory.3) A list of tests, the test procedures, test frequencies and the proposed testing arrangements are provided in Section 3.7 Test Programme.4) The required Record/Reporting Documents for the Consultants Field Staff are also listed in Section 3.7 Test Programme.5) To maintain an auditable and retrievable record of all Inspection Tests, Non-compliance and Corrective Actions etc. the provided proformas must be used by the Consultants Supervisory Staff.6) The Engineer is to ensure that the required tests are performed by the Contractor in accordance with the specified procedures and in the presence of his representative. He is required to maintain a complete record of these test results independently.Classes of ConcreteConcrete for several structures and part thereof shall have 28-day compressive strength of 6 12 cylinders at least equal to the minimum allowable strength shown in the following Table:ClassCompressive Strength at 28-days

Cylinder StrengthN/mm2

A4000 Psi27.58

B3000 Psi20.67

C1500 Psi10.34

* Actual Mix Ratio will be determined after Concrete Mix Design carried out in accordance with relevant Sub-Clauses of Technical Specifications of Contract Documents.Nominal Maximum Aggregate SizeThe nominal maximum aggregate size to be used in various structural components shall be as follows: (Technical Specifications 6.5)General UseNominal Maximum Aggregate Size

Lean Concrete "

Maximum dimension of Structure less than 12"

Maximum dimension of Structure more than 121

Concrete Mix DesignThe mix proportions for class of concrete mentioned in the specifications are nominal. The concrete mix design is required to be carried-out by the contractor under supervision of Engineers representative at field laboratory using cement, sand and aggregates from the approved source of supply. Required average strength used as the basis of selection of concrete proportion, shall be in accordance with ACI 318.The concrete mix design for each class of concrete in addition to mix proportion will also provide water-cement ratio by weight (exclusive of water absorbed by the aggregate) which will be determined on the basis of producing concrete having suitable workability, density, impermeability, durability and the required strength.Concrete Pour AuthorizationThe contractor is required to submit Concrete Pour Authorization (CPA) Request (Refer to Section 3.7 Test Programme) before starting concrete for any component of a structure. The Engineer should check all the items, before allowing pouring of concrete. In case of deficiency, that would be marked on the CPA slip and returned to the Contractor for rectification. The same CPA slip will be finally signed on satisfactory rectification. One copy will be retained by the Engineer for reference and record. Contractors copy should be kept at site by the Contractor.CKL 1.3 (1) CHECKLIST FOR CONCRETE WORKS

Sr.No.IssueAction byRecord/ReportingDocument

1.Physically inspect all the Reinforcement Steel procured by the contractor and confirm adherence to the Specifications by Test Procedures.Lab TechnicianManufacturers Certificate and/or External Lab. Format.

2.Physically inspect, cement procured by the contractor and confirm adherence to the Specifications by Test Procedures. Lab TechnicianManufacturers Certificate and/or External Lab. Format.

3.Physically inspect, fine and coarse aggregates and confirm adherence to the Specifications by Test Procedures.Lab TechnicianRef. Section 3.7

4.Deployment of proper equipment. Discuss with Contractor and EnsureLab TechnicianRef. Section 3.7

5.Receive Concrete Pour Authorization C.P.A. Request from the contractor.Lab TechnicianRef. Section 3.7

6.Check all items of C.P.A. as per requirements of specifications and Drawings and approve.Lab TechnicianRef. Section 3.7

7.Mixing, Transportation and Pouring of Concrete. Check by Physical Inspection and Test Procedure.Lab TechnicianRef. Section 3.7

8.Compressive Strength of Concrete Cylinders. Check by Test Procedures.Lab Technician.Ref. Section 3.7

9.Record of all Tests made during the period. Update Periodically.Lab Technician.Ref. Section 3.7

All actions should be taken in accordance with Contract Specifications and Contractors work methodology as approved by the Engineer.

STONE PITCHING & STONE APRONObjectiveObjective of this Section is to provide the scope of applicability of the recommended guidelines, sequential inspection procedures and other relevant information to the Contractors field staff, for their guidance in performing quality assurance of stone pitching and stone apron to the Permanent Work, being executed by the Contractor.ApplicabilityThis Section covers the placing of stone pitching and stone apron at the specified locations as shown on the drawings. The recommended guidelines can also be used for similar works elsewhere in the project, as directed by the Engineer.Construction EquipmentThe equipment specified in the contract Specifications are only to provide guideline to assist the Contractor in the selection of proper equipment. The Resident Engineer must leave the final selection to the contractor. The Contractor may deploy the following equipment. Rehabilitation and Upgrading of Pakpattan Canal,Khadir Branch and Pakpattan Islam Link Contract: PCSBIP/ICB-01 Excavators Dozer and Rippers Front End Loaders Dump Trucks Water Bowser Dewatering arrangements

Inspection For Quality Assurance (QA) of Construction activities the Contractors Staff shall proceed in accordance with CKL-1.4 Checklist for Stone Pitching & Stone Apron. Base Filter Layer under Stone Pitching shall consist of well graded material as specified in BOQ and shown on the Drawings. The Stones individually shall weigh between 40-120 lbs with 80% shall be 80 lbs or larger and not more than 5% shall weigh less than 40 lbs. All interstices in Stone Pitching/Apron shall be well filled with rock Spalls. The rock Spall shall be rock fragments size between 2 inches and 4 inches. The surface over which the base filter is to be placed shall be trimmed to the proper lines and grades and shall be moistened with water and tamped or rolled with suitable tools or equipment for the purpose of forming a firm foundation. Wherever over-excavation occurs it shall be backfilled with specially compacted fill. The base filter layer shall be placed to a uniform thickness and finished to reasonably smooth and even surface. Stone used in the Stone Pitching/Apron shall be clean rough quarry stone and shall be essentially free from dust, clay, vegetative matter and other deleterious materials. The stone shall be hard, tough, durable, dense, resistant to the action of water and air, and suitable in all respects for the purpose intended. The stones shall be hand packed and placed and bedded in such a manner that the completed stone pitching is stable and without tendency to slide. Construction of stone pitching shall commence at the lowest part of each structure or section of a structure or canal and continue progressively upward. The stones, largest of which shall be used at the bottom, shall be well bedded on a layer of graded Granular Material. In general the size of the stone used shall have its major dimension the depth of the specified pitching. Large open spaces between the stone shall be avoided. Stone shall be placed so as not to project above neat lines shown on the drawings.Quality of StoneWhile performing control over procurement and placement of stone and filter material, the following characteristics of stone and filter material from the specifications must be observed. Stone for pitching/Apron should be dense, sound, angular and resistant to abrasion. The loss in Los Angles Abrasion Test for large size Aggregates (ASTM-C535-96) should not exceed 10% by weight at 200 revolutions or 40% by weight at 1000 revolutions. The loss in Los Angles Test for small size Aggregates (ASTM-C131-96) should not exceed 10% by weight at 100 revolutions or 40% by weight at 500 revolutions. The Specific Gravity of stone (Saturated Surface Dry basis) shall be more than 2.60.Test Procedures Frequency and FacilitiesThe recommended test procedures their frequency and required facilities for an effective quality control of stone pitching and stone apron are presented in QAP/Stone/Test Procedures.CKL 1.4 CHECKLIST FOR STONE PITCHING AND STONE APRON

Sr.No.IssueAction byRecord/ReportingDocument

1.Study and Analyse Contractors Method Statement.

-A. R.E. Rep.- Contractors SurveyorRef. Section 3.7

2.Confirm by Survey Control Levels of TBMs established by the Contractor.

3.Check by Survey Control and Dimensional Inspection Complete setting out/layout as per drawings and specifications.

4.Check by visual Inspection and Survey Control location and level of level pegs. These should be clear of working area.Ref. Section 3.7

5.Check by Physical Inspection and Test Procedures. The Quality of Base Filter Material, Pitching/Apron Stone and Rock Spalls. Cont. site engineerTest Results on External Lab. Format or Field Lab.

6.The material of Base Filter, Stone and Rock Spall should be obtained from approved source.Cont. site engineerRef. Section 3.7

7.Ensure by Physical Inspection Placement of stone pitching and Stone Apron. Cont. site engineerRef. Section 3.7

8.Update Periodically Records of all Tests made during the time period.Cont. site engineerTest Record File

All actions should be taken in accordance with Part Two, Contract Specifications and Contractors work methodology as approved by the Engineer.

BRICKWORKObjectiveObjective of this Section is to provide the recommended guidelines, sequential inspection procedures and other relevant information to the field staff of the consultants, for their guidance in performing Quality Assurance of Brickworks for Structures pertaining to the Permanent Works, being executed by the Contractor.ApplicabilityThis Section covers the construction of Brickworks for brick masonry and brick lining for various Structures, being executed by the Contractor.Construction EquipmentThe Resident Engineer must leave the selection of construction equipment to the Contractor.The Consultants ActionThe Consultants field staff will take appropriate action as recommended in the checklist CKL-1.5 Checklist for Brickwork.Quality of Bricks The bricks should be regular, uniform in shape and size. Bricks over-burnt, under burnt and irregular should not be used. All bricks in oven-dried condition should not absorb more than one sixth of its weight when soaked for one hour in water at 700 F to 800 F and should show no efflorescence on subsequent drying. The average compressive strength of five (5) representative bricks should not be less than 2,000 lbs/in2 when tested in accordance with ASTM.C-67. Each finished brick should be of standard size (9 x 4.5 x 3) first class and weigh between seven (7) and nine (9) pounds. All bricks should have a frog. 0.25deep on upper face. Each brick for lining should have standard size (9 x 4.5 x 3) first class.

2.5.6 Mortar CompositionMortar for all brickwork should have mix ratio as specified in BOQ and sufficient water to produce the proper consistency.2.5.7 Mortar SandMortar Sand should be as per specifications of sand for concrete works.2.5.8 WaterThe water used for preparation of mortar should be free from objectionable quantities of silt, organic matter alkali, salts and other impurities.

CKL 1.5 CHECKLIST FOR BRICKWORK


1.Study and Analyse. Contractors Method Statement.

- A.R.E. Rep.- Contractors SurveyorRef. Section 3.7

2.Check by Survey Control and Dimensional Inspection, complete setting out/layout as per drawings.FR-02 for comments

3.Check by Physical Inspection and Survey Control, location and level of level pegs. These should be clear of working area.

4.Physically inspect Sand, Cement and Bricks and confirm adherence to the specifications by Test Procedure.External Lab or Field Lab Format

5.Discuss with and Ensure, deployment of proper equipment as described in the Work Methodology submitted by the Contractor.A.R.E./Site Inspector/ Cont. site engineerRef. Section 3.7

6.Check all items as per requirements of specifications and drawings. A.R.E./Site Inspector/ Cont. site engineer

7.Update Periodically, records of all Tests made during the period.A.R.E./Field Lab.Test Record Files

All actions should be taken in accordance with Contract Specifications and Contractors Work Methodology as approved by the Engineer.

QUALITY CONTROL PLAN

PREFACESINOHYDRO-NEL Joint Venture is, in particular, responsible for the Quality Control of the Works as per Contract Specifications. Consultants supervision and surveillance does not relieve the Contractor of his contractual obligations. The basic purpose of this plan is to ensure that the Quality Control System is in place and performing to the requirements of Contract documents, during the construction period.The quality requirements are based on technical specifications as per contract documents for Rehabilitation and Upgrading of Pakpattan Canal, Khadir Branch and Pakpattan Islam Link. Maximum efforts have been exerted in making QCP (Quality Control Plan) an acceptable and tangible document for all levels of execution and supervisory staff and novice to experience. The Contract Documents are the basis for this Plan, therefore, where an ambiguity is detected between the procedures and requirements of QCP and content of Contract Documents then the latter takes the precedence.DOCUMENT CONTROLPurpose The purpose of site document and data control is to ensure that all the quality system documents are properly numbered reviewed and approved prior to issue and communication. They are available at the appropriate locations and changes to them are properly documented, authorized and indicated.

Responsibility Document Controller at site is responsible for the control of all data and documents. Document Controller is responsible for following; Responsible for all incoming and outgoing correspondence, distribution and as filing per SOP. Responsible for all incoming drawings and custodian of the original copy, distributing the controlled copies to the concerned persons. Responsible for getting the documents/drawings from the site. Responsible for keeping safe custody of all contractual documents. Responsible for keeping all permanent / final documents till handing over to Consultant or Clients. Responsible for maintaining the document register. He shall establish the filing system accordingly. This may be amended from time to time to current requirement.Incoming & Outgoing Correspondence: All Incoming correspondence from Consultant & client shall be separately filed and issue the copies to the concerned persons. A separate register / electronic file shall be maintained. All incoming correspondence from sub-contractor / supplier shall be filed separately in different folder for each & necessary action. All outgoing correspondence to Consultant & Clients shall have complete reference.Contractual DocumentsAll original contract documents shall be in the custody of Head office in Lahore. A copy shall be available at site for reference.Internal DistributionAs soon as information received from the Consultant or Client, Project Manager shall mark the distribution as required for necessary action / information; if the information needs to be passed to subcontractor it shall be forwarded with a copy along with a covering letter to subcontractor / supplier for their action.TraceabilityAll documents shall be filed in a systematic / functional way marking index, contents of the file, project so as to trace the required document. A master index shall be maintained by the Document controller.Confidentiality of DocumentsAll documents shall be controlled by document controller only and shall be kept in a separate room with lock and key facility so that no unauthorized personnel can access to document room.

PROCUREMENT CONTROL

Purpose To ensure that procurement / purchasing activity at site conforms to SINOHYDRO-NEL JOINT VENTURE procedures and agreed/specified requirements.

Scope This procedure applies to Supplier evaluation & SINOHYDRO-NEL JOINT VENTURE action, procurement of products, documents and verification of purchased products.

Responsibilities The In-charge Procurement at Site is responsible for the following: Sourcing and recommendation of suppliers for construction materials. Maintaining complete record of supplied items, materials, goods, components or services etc. Developing and maintaining an approved vendor/ supplier list. Ensuring timely supply of materials in the right quantity and of the specified/agreed quality/standard. Co-ordination of Procurement functions with Site QA/QC for in-coming inspections. Maintaining Purchase Requisitions, Purchase Orders, Delivery Challans, Material Receiving & Acceptance Reports and Invoices of Suppliers.

Types & Classification of ProcurementMajor procurement at site will constitute the following type of Construction items according to the scope of the project; Civil Mechanical Electrical Services of sub-contractors

Material Procurement & Source Approval In order to get the desired progress, Procurement In-charge is responsible for managing procurement activities. The SINOHYDRO-NEL JOINT VENTURE will obtain source approval; submittals will include the name and address of all manufacturers and suppliers, test results showing complete compliance with the Specifications and specified Standards, the date of manufacture and storage condition, shelf life if appropriate. In addition, the Contractor shall provide representative samples of the materials of sufficient size such that the Engineer may perform all specific tests. Once source approval has been granted by the Engineer all deliveries of the material to the site must in turn be submitted for approval accompanied by all relevant test reports to show full compliance of the material with the Specifications. Where the required tests cannot be performed at the site laboratory, then the Contractor shall arrange for independent testing at a laboratory approved by the Engineer, to be performed to show that the material complies with the Specifications. Cost of such testing shall not be reimbursed.Services of Sub-ContractorsSINOHYDRO-NEL JOINT VENTURE will endeavor to perform all the major works by his own team but few specialized jobs, like specialized Mechanical gates etc. are planned to be awarded to the specialized sub-contractor after the prior approval from the Client / Engineer. SINOHYDRO-NEL JOINT VENTURE will be fully responsible for any part of the works performed by him or his subcontractor(s) and for the acts and omission of the subcontractor.

CONSTRUCTION MATERIAL CONTROL

Purpose To establish and maintain a unique identification and record system to trace the history, location, quality and application of the material. To identify the material during all stages of construction through the drawings & specifications and processes.

Scope This procedure is applied for this project, including project management and project Site.

Responsibilities Store in-charge & Store Keeper at site are responsible to ensure that construction material records are maintained and procedures followed to establish a unique identification and traceability for each material. Procedures Site Stores is to ensure that all items are properly identified with their unique identification names and codes. The Store in-charge is responsible to ensure that all quality records and documentation used for the transaction of materials include their proper identification.

The Construction Manager(s) at site are responsible to ensure that the following identification and traceability procedures are followed:

The Material on the project Site is to be marked with a unique Identification method for its proper recognition, identification of location, product and materials by reference to the drawings and specifications. The Construction Managers along with his project team is responsible to identify the need & methods of these unique identifications.

The work done during the tenure of the Project is to be appropriately documented to ensure that all inter-related activities, material and products are traceable to each other and their sources.

PROJECT PROCESSES

Purpose To provide a system for effective Project planning, Execution and Control of various project processes during construction phase of the project.Scope This procedure is applicable to the following processes at site. a) Project Quality Management. Project Planning. Resource Planning (Man, Machine & Materials). Organization. Monitoring and Control. b) Project Mobilization. c) Execution. Methods. Specifications. Process Validation. Inspection & Testing. d) Safety, Health and Environment. e) Maintenance of Equipment & Tools.

Responsibilities The Project Manager is responsible to ensure that this procedure is effectively being implemented.

Project Quality Management Project Quality Management at site is to include planning, organizing, monitoring & controlling processes. The objectives of this quality management apply to all Project Management Processes.

Project Planning Each contract shall have project planning for effective resource and execution schedule planning. For that purpose detailed construction schedule plan shall be prepared and implemented during construction phase. Project planning includes but not limited to Work, Activity base planning, Resource planning and establishment of progress review system for proper implementation.

Resource Planning Overall Resource Planning for the project shall be done for Manpower, Machines and Materials in accordance with each applicable contract. Project resource planning shall be done for the project by breaking the phases & processes into sub-processes. Project Organization The site will plan its organization to undertake project assignments in accordance with the Project Resource and Execution plan. This Project organization is the owner of all processes at site.

Project Monitoring & Control To effectively monitor and control the project specifications and schedule, the following reports are to be generated at indicated intervals for reviewing and necessary action: Daily Progress Report Weekly Progress Report Monthly Progress Report

Project Mobilization The Project Manager is responsible along with his project team to define and develop a project mobilization plan.

The Mobilization plan will include the following: 1. Mobilization of Temporary Facilities 2. Manpower 3. Equipment & Machines 4. Facility Layout

ExecutionMethods & SpecificationsThe client as a basis has provided standard execution procedures and specifications for preparation of work methodology. Methodology is to be prepared by the Planning Section in each discipline in consultation with field staff. The Methodology is to be prepared for each execution process, reviewed by Project Manager. During the start of every project activity, Consultant validated and approved Methods are to be made part of the Quality Control Plan (QCP).Inspection and TestingInspection and Testing shall to be incorporated in the methods, which shall be applied after validation by the consultant. The Site execution is responsible to proceed according to the Method while QA/QC team is responsible to apply during each process. Approved third-party inspection and testing facilities may be utilized if required. The procedure and applicable records are explained in the section dealing with Inspection and testing.

Process ValidationIn order to ensure appropriate level of conformance to the process validation, the site QA/QC team shall plan and execute internal audits of the site from time to time.

Safety, Health and Environment Environmental Management Plan given by Client in Contract Document (Vol-2) will be used as Safety, Health and Environment Manual. All the preventive measures during construction phase will be taken as per EMP. HSE Manager is responsible for all Health, Safety, Security and an Environmental issue arises during the execution of the project. To effectively monitor and control the projects Health, Safety & Environmental issues, following plans & reports are to be generated for reviewing and necessary action:

Site Specific Environmental Management Plan Daily, Weekly & Monthly HSE Performance Reports Site Safety Inspection Reports. Internal Audit Reports. Accident / Incident Reports Social Compliant Reports Water, Air Quality & Noise Level reports as per EMP. Tool Box Talk / Training Records. Dispensary / Treatment Record. Other reports, Records and Plans as per approved EMP.

Maintenance of Equipment/ Tools To control the process for maintenance of Machinery, Tools and Equipment, Machinery Supervisor is responsible to maintain a complete schedule of preventive and breakdown maintenance of all project vehicles, machinery, tools and equipment.

CALIBRATION OF VARIOUS DEVICES / EQUIPMENTPurpose To ensure a system for calibration and maintenance of Inspection, Measuring and Testing Equipment (IMTE) at Site. Scope This system applies to all activities where IMTEs are used for inspection and testing of parameters that directly effect the quality.Responsibilities QA/QC Manager is responsible for ensuring that the Calibration of all Inspection, Measuring and Testing Equipment (IMTE).ProcedureStandard procedures will be followed to assure that test and measuring devices used to test, or accept materials or components are calibrated at specified intervals to maintain the proper accuracy. Devices used shall be of a proper range, type and sensitivity to reliably measure the parameters being evaluated. The calibration of such devices shall be documented and shall be performed using certified measurement standards and submitted to the Engineer for approval. All IMTE are to be maintained at site in a calibrated condition. In case an IMTE is found to be out of calibration, it is to be segregated from the others and put out of service in the Site store in an area marked OUT OF CALIBRATION.TEST PROGRAMMEQC Testing FacilitiesThe SINOHYDRO-NEL Joint Venture shall ensure that proper representative samples are taken from each lot and sub-lot, identify the tests and analysis required, and ensures that the tests and analyses conducted are in accordance with internationally accepted procedures and standards.As a part of the construction materials QC programme, the SINOHYDRO-NEL Joint Venture shall set up a field laboratory at his own cost. The field laboratory shall be in full working order suitably equipped and staffed to carry out all routine sampling and testing necessary for successful and timely completion of the works according to the specifications.

Tests to be performed at siteThese tests are field specific and include the following:a) Soil Auger sampling, ASTM D-1452 Plasticity Index test, ASTM D-4318 Grain size analysis, ASTM D-422 Moisture density relationship, ASTM D-698 and 1557 Visual identification classification, ASTM D-2488 Classification of soils for engineering purposes, ASTM D-2487 Max. and Min. index densities, ASTM D-4253 and ASTM D-4254 Proctor needle penetration, ASTM D-1558 Moisture content of soils, ASTM D-2216 In-place density, ASTM D-1556, ASTM D-2167 and ASTM D-2937 Specific gravity, ASTM D-854 California Bearing Ratio, CBR AASHTO T-193 or ASTM D-1883 Water Soluble Chloride (CL), B.S. 1377 Water Soluble Sulfate (SO3) B.S. 1377

b) Aggregates and Concrete Sampling of aggregates, ASTM D-75 Sampling of fresh concrete, ASTM C-172 Sieve analysis of aggregates, ASTM C-136 Specific gravity and absorption of aggregates, ASTM C-127 and ASTM C-128 Slump of concrete, ASTM C-143 Unit weight of fresh concrete, ASTM C-138 Unit weight of aggregates, ASTM C-29 Making and curing of concrete cylinders, ASTM C-31 Compressive strength of concrete cylinder ASTMC39 Water Soluble Chloride (Cl) ASTM C1812 or BS 812 Water Soluble Sulfates (SO3) BS 1377

c) Stone Los Angeles Abrasion Test for Stone.

Tests to be performed at Field Laboratory The tests to be performed at Contractors Field Laboratory include the following but not limited to these: Soil classification Tests Compaction Tests Gradation Analysis of Aggregates as required by R.E. 7 and 28 days compressive Strength Tests on concrete cylinders. Unit Weight of aggregates. Fresh Density of concrete. Absorption and Compressive Strength of bricks. Specific Gravity and Absorption of coarse and fine aggregates. Los Angeles Abrasion Test for Coarse Aggregate Soundness of Aggregate

Test to be performed at external laboratories/ Consultants laboratoryThese tests can only be performed in specified off-site laboratories and include tests on reinforcing steel, cement, abrasion, petrography, soundness of concrete aggregates, water stop and any other tests required during any problem or dispute.

TESTING ARRANGEMENTS/EQUIPMENTSTesting at Construction SiteThe Contractor for an individual contract package shall be responsible for providing the equipment and carrying out these tests in accordance with the Technical Specifications under the direct supervision and guidance of the Consultants supervision staff.The contractor is required to provide and readily make available at construction site the following equipment, Earthwork: Sand - Cone Density Apparatus, complete with base plate and sand bottle. Density Core Cutter 4 dia, complete with collar and hammer. Speedy Moisture Tester capacity 20.0 gm. Moisture range 0 20% complete with electronic balance and plastic carrying case. Balance Triple Beam 2610 gm capacity with readability of 0.10 gm. Balance 30 Kgs capacity with readability 1.0 gm. Drying Oven capacity 108 Litres.

Concrete Work: Cylinder moulds for concrete 6 dia. Complete with tamping rod (5/8 in dia 20 long) and mallet. Slump Test Equipment complete with tamping rod 5/8 dia and 24 long. Curing Tanks These shall be constructed close to the construction site for storing concrete cylinders till their transportation to the Laboratory for testing. A reliable compression machine approved by the Consultants Material Engineer. Thermometers to check fresh concrete temperature.Note: The Contractor shall ensure that sufficient No. of the above equipment is available at site to satisfy the testing requirements of the quantum of work. Computers with printers should be provided in laboratory.Testing in the Engineers Field Laboratory A material testing laboratory established at site should be equipped and adequately staffed to carry out the field laboratory tests as per requirements. This Field Laboratory, established by the contractor and supervised by the Consultants Quality Control / Assurance staff is to carry out the required tests and maintain a systematic and retrievable record. Test record should be computerized. All Quality Control/Quality Assurance tests specified to be performed in the field laboratory shall be carried at the designated Field Laboratory at site. (Individual arrangements by the contractors for this category of tests shall not be acceptable. The Contractors shall be responsible for providing and transporting the test specimens to the laboratory under the guidance and supervision of the Consultants Resident Engineer. The contractors shall bear the cost of these tests as per rate list available at any Field or external Laboratory specified by the Engineer.Testing from External LaboratoryThe Quality Control tests to be carried out from an external laboratory defined in are recommended to be carried out at laboratories mentioned below or as directed by the Engineer. The cost of transportation and testing charges shall be the Contractors responsibility. Following or any laboratory specified by the Engineer shall be used for external testing; Central Material Testing Laboratory (CMTL) WAPDA Lahore. University of Engineering & Technology Lahore. Punjab University (Environment and Soil College). PCSIR Laboratories Lahore and Karachi. Cement Research & Development institute Kot Lakhpat, Lahore. Pakistan Standard and Quality Control authority. In PITAC Compound, Lahore.TESTING REQUIREMENTSThe test procedures and the test frequencies for the various construction works have been summarized in the following tables.

MaterialTestDesignationTesting Frequency

SOIL

Grain Size AnalysisASTM D-4221 for 30,000 cft

Liquid LimitASTM D-43181 for 50,000 cft

Plastic LimitASTM D-43181 for 50,000 cft

Shrinkage LimitASTM D-4271 for 50,000 cft

Moisture Density RelationshipASTM D-6981 for 50,000 cft

Moisture Density RelationshipASTM D-15571 for 50,000 cft

Field Density for EmbankmentASTM D-15561 for 20,000 cft

Field Density for BackfillASTM D-15561 for 5,000 cft

Moisture ContentASTM D-566 or ASTM D-22161 for 7,500 cft (min. 2 for each layer)

Specific GravityASTM D-854Min. 3 per source or type of material or as directed by the Engineer

Relative dry densityASTM D-4253 & ASTM D-42541 for 10,000 cft or as required by the Engineer

CBRAASHTO T193As required

COARSE AGGREGATE

Sieve AnalysisASTM C-1361 for 7,000 cft

Material Passing # 200 SieveASTM C-1171 for 7,000 cft

Unit WeightASTM C-291 for 17,500 cft

Specific Gravity and AbsorptionASTM C-127 & ASTM C-1281 for 17,500 cft

Moisture ContentASTM C-5661 for 17,500 cft

SoundnessASTM C-881 for 70,000 cft

Los Angles AbrasionASTM C-1311 for 70,000 cft

Clay Lumps & Friable ParticlesASTM C-1421 for 70,000 cft

Petrographic AnalysisASTM C-2953 for each source

Lightweight ParticlesASTM C-1231 for 70,000 cft

Water Soluble (Cl)Water Soluble (SO3)

ASTM C-1812, or BS 812BS 13771 per lot / source or as directed by the Engineer

FINE AGGREGATE

Sieve AnalysisASTM C-1361 for 5,000 cft

Material Passing #200 SieveASTM C-1171 for 5,000 cft

Unit WeightASTM C-291 for 10,000 cft

Specific Gravity and AbsorptionASTM C-1281 for 10,000 cft

Moisture ContentASTM C-5661 for 10,000 cft

SoundnessASTM C-881 for 50,000 cft

MaterialTestDesignationTesting Frequency

Clay Lumps & Friable ParticlesASTM C-1421 for 35,000 cft

Sand EquivalentASTM C-24191 for 35,000 cft

Organic ImpuritiesASTM C-405 per each source

Lightweight ParticlesASTM C-1231 for 50,000 cft

Petrographic AnalysisASTM C-2953 for each source

Water Soluble atWater Soluble SO3ASTM C-1812, or BS 812BS 13771 per lot / source or as directed by the Engineer

CEMENT

Setting TimeASTM C-1911 per lot or 2500 bags

Mortar StrengthASTM C-1091 per lot or 2500 bags

Complete Chemical AnalysisASTM C-114As required

REINFORCEMENT

Size and weightASTM 615As required

ElongationASTM 615As required

BendingASTM 615As required

Tensile StrengthASTM 615As required

Complete Chemical AnalysisASTM 615As required

WATER

Complete Chemical AnalysisOnce a month/Source

CONCRETEMaking and curing concrete specimenASTM C-31As required

Compressive StrengthASTM C-391 for 2,000 cft

SlumpASTM C-1431 for 2,000 cft

Air ContentASTM C-2311 for 2,000 cft

Temperature1 for 1,000 cft

Fresh DensityASTM C-1381 for 5,000 cft

ADMIXTURES

Air EntrainingASTM C-260As required by the Engr.

Chemical Admixtures for ConcreteASTM C-494As required by the Engr.

Curing CompoundASTM C-309As required by the Engr.

OTHERS

Joint FillerASTM D 1752-84As required by the Engr.

Joint SealantASTM C 920-98As required by the Engr.

WaterstopUS Federal TestMethod Standard No.601As required by the Engr.

QC Test ResultsAll QC tests results shall be submitted to the Engineer for his review and acceptance. The test results must show full compliance with the Specifications, in order for the works to be approved.

a) Soil reports showing locations, material source, material type, density, moisture content, density-moisture content relationship, degree of compaction (RC) and relative density where applicable.b) Concrete reports showing source of all constituents, testing of source material, date of manufacture, testing of material after processing, including determination of moisture content of aggregates and testing manufactured concrete, concrete slump, compressive strength, temperature during placement etc. Certification of all cement supplies, and storage records.c) Aggregates reports for filters, base course, showing source of material, test results showing compliance with the specification and placing location.d) Ancillary reports for materials such as steel, pre-stressing strand, jointing compound, sealant etc., showing name of source, date of manufacturers shelf life, storage conditions, place of storage, test results showing compliance with the specification and placing records.

QUALITY RECORDS

Purpose To provide a system for identification, collection, indexing, filing, storage, maintenance and disposition of quality records at Site.

Scope Documents consist of recording formats, which furnish objective evidence of the extent of the fulfillment of the requirements for quality. Quality Records to be used at Site consist of Consultant / Client specified or site specified formats.

Responsibilities QA/QC team at site is responsible to ensure that quality records are distributed, maintained and controlled at each owner department/section through the project execution. QA/QC team is responsible to generate the filled formats of quality records. They will ensure their maintenance and distribution.Procedure

Identification Records are to be recorded on specified Performas as given in Table 3.1. Records are to be identifiable to the product, person or event to which they pertain. Records are to be dated, and signed by the person who establishes the record. Records are to be indexed and grouped, where necessary, to facilitate their retrieval. Records are to be signed by the Engineer Representative for validation / approval if required.

Retention of Records The retention period of records is to be established for the periods during which the record may be required for study or verification in accordance with the contract.

Storage Records are to be stored in files that are to be properly numbered and indexed for easy retrieval and to avoid damage. Cabinets containing records are properly labeled to display their contents.

Laboratory Record/Reporting DocumentsTable: 3.1Laboratory Record/Reporting Documents

( Field Laboratory )

Document No.Document Description

SOIL

LR-01Particle Size Analysis of Soil

LR-02Moisture Content of Soils

LR-03Liquid Limit, Plastic Limit and Plasticity Index of Soils

LR-04Specific Gravity of Fine Grained Soil Particles

LR-05Laboratory Compaction characteristics of soils

LR-06Field Density & Degree Of Compaction of Non cohesive soils

LR-07Field Density & Degree Of Compaction of cohesive soils

LR-08Summary of Compaction Control Test for Cohesive soils

LR-09Summary of Compaction Control Test for Cohesion less soils

LR-10Sieve Analysis ( Hydrometer Method) and its Graph

LR-11Field Density Test Core Cutter Method

CONCRETE

LR-12Particle Size Distribution of Concrete Aggregates

LR-13Concrete Compressive Strength

LR-14Request for concrete pour Authorization

LR-15Flakiness and Elongation index

LR-16Concrete Cylinders/Cubes Casting and Delivery Report

LR-17Summary of Cylinders/Cubes Test Result

LR-18Concrete Mix Design

LR-19Concrete Delivery Slip

LR-20Concrete Delivery Record Summary

LR-21Concrete Pouring Record Summary

LR-22Unit Weight Of Aggregates

LR-23Specific Gravity of Coarse Aggregates

LR-24Specific Gravity of Fine Aggregates

LR-25Blend Of Aggregates & sand

LR-26Moisture Content of Aggregates

LR-27Unit Weight and Yield of Fresh Concrete

LR-28Sand Equivalent

LR-29Sulphate Soundness

LR-30Density of Bentonitic Slurries

LR-31Concrete Pour Authorization

LR-32Tendon Stressing Record /Post Tensioned Concrete

LR-33Clay Lumps and Friable Particles

LR-34Concrete Mix Design Summary

LR-35Concrete Batch Plant Calibration

LR-36Curing Tank Record

LR-37Test Report Summary of Coarse Aggregates

LR-38Test Report Summary of Fine Aggregates

LR-39Sieve Analysis Passing # 200 Sieve

Misc.

LR-40Weather Record

LR-41Monthly Lab Test Summary

LR-42Stone Pitching

LR-43Bricks Tests Report

LR-44Bricks Testing Summary

LR-45Speedy Calibration and its Graph

LR-46Cone Calibration and Unit Weight

LR-47Daily Lab Progress Report

LR-48Los Angles Abrasion Test

LR-49Material Approval Submittal

LS-01Survey Level Sheet

BB-01Format for Bar Bending Schedule

FR-01Check Request

FR-02Field Note

Note: FR = Field Record, LS = Level Sheet, BB = Bar Bending Schedule

Note: All above listed documents are given in ANNEXURE B. TRAINING

PURPOSE To establish a system for determining the need of staffs training, providing training and maintain training records at site.

SCOPE This procedure applies to all training programs provided by SINOHYDRO-NEL JOINT VENTURE at site.

RESPONSIBILITIES PM and SM are responsible for identifying and recommending employees after assessing the training needs of their staff.

Manager Admin is responsible for the following:

Arranging training of recommended Site employees. Keeping record of external training of Site employees. Arrange orientation on quality assurance and maintaining relevant record for the site. Arrange orientation and maintain record at Site for new appointees/transferred personnel. Maintaining the record for internal/external training of Project Site personnel.

PROCEDURE Orientation Arrangements for orientation of new appointees/transferees are to be made by the Manager Admin at site in the following areas;

General rules and regulation of the company/Site rules & regulations. Project Orientation. Companys Quality Policy and System. Departmental Operations and Job descriptions. Safety policy & rules.

Training record of above-mentioned orientation is to be maintained.Training NeedsIt is the responsibility of the PM and Site Manager to identify training needs for their staff. They are to determine training needs by observing the following;

Skill and Work Know-how and practices of the employees. Nonconformities detected in the process or internal quality audits. Any other non-conformity in construction methodology & procedures may imply a training need.

The needs, thus identified are to be forwarded to the Manager Admin.

The request is to be evaluated and treated in accordance with the review, feasibility and importance. Appropriate arrangements are to be made if approved. TRAINING RECORD Internal Based on the training course attended by the employee training record is to be updated.External After successful completion of external training the employee is to submit a copy of the training certificate to Manager Admin for record in his personal file.INTERNAL QUALITY AUDITS Purpose To provide a system for conducting Internal Quality Audits and determine whether quality of activities and related results are complying with planned arrangements and whether these arrangements are implemented effectively. Scope This procedure is applicable to all Site activities falling within the quality system. Responsibility Project Manager & Site Manager at Site are responsible for establishing the team, to perform Internal Quality Audit. P.M. will be the head of the audit team. Site Manager, Planning Engineer and Construction Managers shall be the members of Audit Team.

Procedure To provide a procedure for conducting Internal Quality Audits and to determine whether the site Quality Assurance activities are conforming to the system, giving the desired results and complies with plans, quality audit process is as follows.Quality audit process

Audit ProgramThe Audit Team Leader shall do the following:- Prepare an Audit Program listing the Manpower and its individual responsibilities Infrastructure requirements, type and duration Period of Audit Relevant Notes, Checklists and Time Sheets Working Files of Previous Audits, if any, for clearance of the outstanding matters. Informing the Scope of Audit Providing the QC Team with a list of requirements especially documents and availability of personnel who may be needed including duration

Meeting with QC TeamThe Team Leader of Audit Team should always ensure that his audit would not disrupt the duties of the QC Team and his staff nor hinder the smooth operations of the department being audited. Thus it is of utmost important that he is exible and as far as practicable to accommodate the needs of the QC Team. During The AuditThe Audit Team should then commence his audit systematically and in accordance with the approved program. The Audit Team should ensure the following:

Have an opening conference with the QC Team and those involved in explaining the scope, duration and need for documents etc. and providing explanations as necessary Visiting the site of the project, obtaining a brieng and getting the feel of the works, site conditions, progress, materials, etc. Documents or any changes to terms & conditions in standard forms or company approved formats / procedures. Clarify and obtain explanations and remedy where necessary with verbal or written responses.

At The End of AuditThe Audit Team should have a final closing meeting with the QC Team covering all relevant matters. The result of the discussions should be documented Instances where the QC Team disputes the Audit Teams ndings or does not agree with his views and recommendations should be recorded together with the QC Teams rationale and supporting reasons Prepare a Draft Final Audit Report and send it to the Management and other relevant persons for their review. Prepare and issue a Final Audit Report

ANNEXURE A(Organogram)

ANNEXURE BQA/QC Reporting Documents

Quality Control Plan

Documents

Transcript of Quality Control Plan