Quality Assessment Study Capacity Building of Department of Roads Bridge Improvement and Maintenance Project (BIMP) Edited by: Chandra Shrestha Original.

Quality Assessment Study Capacity Building of Department of Roads

Bridge Improvement and Maintenance Project (BIMP)

Edited by: Chandra ShresthaEdited by: Chandra ShresthaOriginal authors: Rod/BhagwanOriginal authors: Rod/Bhagwan

Department of RoadsDepartment of RoadsMinistry of Physical Planning & WorksMinistry of Physical Planning & Works

QA in Projects supervised by QA in Projects supervised by ConsultantsConsultants

The quality control procedures adopted on projects supervised by consultants is generally considered satisfactory

Adequate laboratory & testing facilities are generally provided (& paid under the contract) by the Contractor

Projects supervised by the Projects supervised by the employer/DoRemployer/DoR

The quality control procedures for projects supervised by DOR staff were less rigorous than those where a Consultant is engaged

Due to the absence of dedicated laboratory facilities & the lack of independent staff for testing

QAP frequently not submitted

(c) Works undertaken by DROs(c) Works undertaken by DROs

The laboratory and testing facilities within the DROs are inadequate and are poorly maintained and managed

Insufficient staff are deputed to work in the Labs and few are appropriately trained or experienced.

Much of DRO work is off-SRN (ie on LRN)Much of DRO work is off-SRN (ie on LRN)

Activities of the Central Roads LabActivities of the Central Roads Lab

CRL functions comparatively efficiently and autonomously, but lacks a clearly defined role and purpose

Current staffing levels are inadequate and much of the equipment is in desperate need of replacement, repair or upgrading

Institutional Arrangements for QAInstitutional Arrangements for QAEstablishment of a “Quality Control Unit” in Planning & Design Branch (1 SDE + 1 Eng) was approved in 2000 (2057) – not implementedDoR Current Organisation includes “Asset Management, Contract Management & QC Project” (AMCMQCP) directly under DG - but with no specific provision for QC UnitNo specific responsibility for QC assigned in DoR – although RD is mandated to perform quality checks (not regularly undertaken)

Findings regarding QA in DoRFindings regarding QA in DoRSupervision & quality control is very weak in the DROs and projects (w/o Consultants)The main reasons are:• No clear cut responsibility/accountability between

staff for supervision of works• No proper and close monitoring system for

supervision• No strict adherence for submission or compliance

with QAP• No proper lab set up (cont…)

Findings regarding QA in DoR Findings regarding QA in DoR (2)(2)

• Low priority for management of Lab and testing of the materials

• Test reports are required only for payment• Samples taken by the Supervising team without

knowledge of sampling and testing• Site Engineer acts as lab-in-charge for his works

and checks/approves the test report• SDE not interested in the Lab or testing • No monitoring system for quality control• Lack of trained Lab Technician and Lab Assistant

Requirements for Sustainable QARequirements for Sustainable QADROs & projects w/o consultants supervision:• Staffing vacancies to be filled• One Engineer deputed as Lab-in-charge• Submission of QAP to be mandatory• 10 basic tests to be conducted in each DRO Lab as

per specification & frequency• DRO Labs to be upgraded as defined (see next slides)

• Detailed records to be maintained & filed

DRO Labs to be upgraded (1)DRO Labs to be upgraded (1)DRO Labs to be upgraded:• adequate space provided with concrete floor;• vibrating equipment to be bolted down;• working tables provided to conduct tests;• equipment etc organized & kept in proper place; • fragile items to be stored separately;• Expensive/sensitive equipment to be locked up; • racks and/or cupboards to be provided; • equipment & accessories to be cleaned after use;

(cont…)

DRO Labs to be upgraded (2)DRO Labs to be upgraded (2)DRO Labs to be upgraded (continued):• simple maintenance to be performed regularly &

equipment maintained as per guidelines; • Lab should be kept clean; • broken equipment to be repaired or auctioned &

new equipment purchased, if required;• equipment requiring calibration to be labeled with

details of calibration required (when & where);• the minimum load to be read for the mortar cube

compressive test should be 100 Kgf

Recommendations for CRL (1)Recommendations for CRL (1)

CRL to be strengthened & fully staffed as a separate unit under an SDE, with 1 Engineer, Lab Technicians and Ass’t Lab Technicians CRL to undertake all required tests, including rebar using UTM, calibration of equipment from other Labs and Non-Destructive Testing for bridge projects. UTM & Non-Destructive Testing equipment to be purchased & staff trained (cont…)

Recommendations for CRL (2)Recommendations for CRL (2)

Vacant posts to be filled – Engineer to be appointed to act in absence of SDE (chief)Detailed job descriptions to be preparedPost of Supervisor to be createdEquipment to be repaired/maintained24hr back-up generator of adequate capacityLab & compound to be kept clean & tidyRegister of all samples & tests to be kept

Institutional RecommendationsInstitutional Recommendations1 Engineer to be designated as Lab-in-charge in each DRO & responsible for QA activitiesPermanent QC Unit to be established in DoR with appropriate powers to interveneRDs to conduct visits to supervise, monitor & evaluate the quality control aspects of worksSenior Materials Engineer to be appointed in each RD to monitor Lab tests in DROs

Training NeedsTraining NeedsLab Techs & Assist’s to be trained to conduct all tests performed at DRO LabsPeriodic refresher training as req’d & records kept of training receivedLab-in-charge must be capable of checking & verifying results of testsAll training to be conducted/organised by CRL2-day training programme for 100 Engineers to raise awareness within DoR

QA requirements for BIMPQA requirements for BIMPContractor should establish an on-site Lab for new bridge construction: for maintenance works Contractor should use DRO LabAll Contractors to submit QAP & to be All Contractors to submit QAP & to be approved before startapproved before startDRO/RD to supervise & ensure QAP followedDRO/RD to supervise & ensure QAP followedRegular 4 monthly monitoring & Quality Audit Regular 4 monthly monitoring & Quality Audit by independent consultantby independent consultantNon-Destructive Testing of quality & strength Non-Destructive Testing of quality & strength of concrete to be performed by private Labsof concrete to be performed by private Labs

Overall Findings, Conclusions Overall Findings, Conclusions & Recommendations& Recommendations

Overall FindingsOverall FindingsExisting QA procedures are not effectiveDirectives & Regulations are adequate – but are not rigorously enforcedPayments can be made without test resultsConflicts of interest occur – lack of impartialityProblems most severe in DoR-managed projectsCRL & DRO Labs have most equipment required but condition of labs & equipment is poorAppropriate staff not deputed to perform tests & training is insufficient

ConclusionsConclusionsNecessary to amend legislation so that existing Directives & Rules are followed & to ensure that payments are conditional on QA processOperation of DoR testing facilities (CRL&DRO) should be improved – equipment maintained & staff trained to perform tests effectivelyResponsibility for the QA process rests with the RDs, supported by CRL to provide training & check on Lab facilities & capabilities

RecommendationsRecommendationsCompletion of all QA measures to be made a mandatory requirement of the Internal AuditQA procedures to be formalised within the proposed CMS – payment only when QA completeThe CRL & DRO Labs to be maintained, staffed & operated: 1 engineer deputed as ‘in-charge’Revised procedures, manuals & guidelines for DRO Labs to be provided by CRL

Action PlanAction PlanAction Timing Responsibility

1 Improve DRO Labs & fill vacancies 4 mths DoR/DRO

2 Transform AMCMQCP into QCU 3 mths DoR

3 Depute Lab-in-Charge in all DROs 1 mth DRO

4 Improvements to CRL: clean, new equipment, etc 1-4 mths DoR/CRL

5 Training for Lab-in-Charge, Lab Techs, etc annually QCU/DoR

6 Revise Manuals, Guidelines, Policy, etc 4 mths QCU/DoR

7 Clarify staff responsibilities & accountability 4 mths DoR

8 Provide Snr Materials Eng/QCE in RDO 4 mths DoR/RD

9 Set up Unit in CRL for UTM, NDT & calibration 4 mths QCU/CRL

10 Provide Supervisor in CRL 4 mths CRL

Laboratory PhotographsLaboratory PhotographsBiratnagar – adequate space & some new equipmentBiratnagar – adequate space & some new equipment

Laboratory PhotographsLaboratory PhotographsButwal – adequate space but equipment not fixedButwal – adequate space but equipment not fixed

Laboratory PhotographsLaboratory PhotographsPokhara – some Pokhara – some new equipmentnew equipment Nuwakot– limited Nuwakot– limited

equipmentequipment

Laboratory PhotographsLaboratory PhotographsKathmandu – cramped & Kathmandu – cramped &

equipment dumpedequipment dumpedLalitpur – new facilityLalitpur – new facility

Laboratory PhotographsLaboratory PhotographsCRL – adequate space but equipment old & needs CRL – adequate space but equipment old & needs

repair repair

Thank YouThank You

Workshop on 3 June 2-12Workshop on 3 June 2-12

Discussion groupsDiscussion groups– Group A: Legal issuesGroup A: Legal issues– Group B: Central Research Laboratory Group B: Central Research Laboratory

StrengtheningStrengthening– Group C: Divisional Level Strengthening Group C: Divisional Level Strengthening – Group D: Organisational issuesGroup D: Organisational issues

Group A: Legal IssuesGroup A: Legal Issues

Basis for accepting bidsBasis for accepting bids

Simplification of test requirements for Simplification of test requirements for small contractssmall contracts

No competition on test requirements No competition on test requirements (provision through PS)(provision through PS)

abnormally low biddingabnormally low bidding

6 Million ceiling for non-qualified user 6 Million ceiling for non-qualified user committees to be reviewedcommittees to be reviewed

Group B: CRL StrengtheningGroup B: CRL Strengthening

Insufficient Trained ManpowerInsufficient Trained Manpower

Insufficient Equipment (Lab)Insufficient Equipment (Lab)

Provide non disruptive testProvide non disruptive test

UTM PurchaseUTM Purchase

Technical Personnel are reluctant to Technical Personnel are reluctant to engage in CRL engage in CRL

Traditional record keeping systemTraditional record keeping system

Unclear ToR of CRLUnclear ToR of CRL

Group C: Strengthening of Divisional Group C: Strengthening of Divisional LaboratoriesLaboratories

Upgrade existing lab with additional spaceUpgrade existing lab with additional space

Additional budget and human resourcesAdditional budget and human resources

A dedicated vehicle for the labA dedicated vehicle for the lab

Retention of 50% revenue generated by Retention of 50% revenue generated by labslabs

Group D: Organisational IssuesGroup D: Organisational Issues

Make contractor accountable for quality Make contractor accountable for quality assuranceassurance

Provision of lab facilities at Divisional Provision of lab facilities at Divisional offices and convert CRL to Central Road offices and convert CRL to Central Road Research and LaboratoryResearch and Laboratory

Outsource additional expertise if requiredOutsource additional expertise if required