SALIENT ASPECTS OF QUALITY ASSURANCE & QUALITY CONTROL CONSULTANCY FOR NSP MODERNISATION & REHABILITATION WORKS UNDER APWSIP G.PRABHAKAR FIE.

SALIENT ASPECTS OF

QUALITY ASSURANCE & QUALITY CONTROL CONSULTANCY FOR NSP

MODERNISATION & REHABILITATION WORKS UNDER APWSIP

G.PRABHAKAR FIE

PREAMBLE

In order to attain the best and sustainable quality of construction, Govt. and World Bank desired to appoint. THIRD PARTY

QUALITY ASSURANCE / CONTROL CONSULTANTS to work in coordination

with the Project Engineers.

PRINCIPLES OF QUALITY

• Quality planning prevents pathetic performance. Quality lives on long after the price is forgotten.

What is Quality ?

• Fit for purpose, suitable for the intended purpose.

• Many experts defined Quality in many ways.JURAN (father of quality or a quality guru) defined that

• a greater number of features that meet customer needs and has

• fewer deficiencies.

PHILIP CROSBY defined that

Quality is that which meets every possible technical specifications and it consists of

1. Design 2. Make it , test it3. Use it 4. Test it in service

EDWARDS DEMING defined as Conformance to requirement

QUALITY PLANNING

• to establish quality goals.• to identify the needs of work.• to develop process which enables to

produce the desired specifications.• to establish process controls.

QUALITY IMPROVEMENT

• to establish infrastructure.• to establish project team.• to provide the team with resources

training.

QUALITY ASSURANCE

• Assurance : The act of giving confidence, the state of being certain

or the act of making certain

• Quality Assurance: The planned and systematic activities implemented in a

quality system so that quality requirements for a product will be fulfilled.

QUALITY ASSURED BY

• Quality of • Input Materials

Adherence to specifications

Quality of end product

QUALITY CONTROL

• CONTROL : An evaluation to indicate needed corrective responses, the act of guiding a process in which variability is attributable to a constant system of chance causes.

• QUALITY CONTROL: The observation techniques and activities used to fulfill requirement for quality.

Rehabilitation & Modernizations works relating to - Main Canals ..2 (Right 203 Km + Left 297 Km)- Branch Canals 16 (Right (9) 269 Km + left (7) 198Km)- Major Distributories : 158 and entire Network of distribution.- Dam Safety Works- Lift Irrigation Schemes 165These works involve types of construction,

construction Materials and procedures / Techniques.

INTRODUCTION

i) to monitor the quantity and progress.ii) to ensure strict enforcement of specifications by

developing check lists, OK Cardsiii) to develop formats for testing different items of

input materials and finished items of work.iv) to conduct training to the key personnel of all

project related agencies.

CONSULTANTS TO PROVIDES THE SERVICES

A. CONTRACTOR (Party- I). Worker programme – Quality Management plan

shall be handed over to the site Engineer & Consultants.

. Shall have adequate Lab. Arrangement for conducting 100% quality tests.

. Shall maintain OK cards – before commencement during execution and after completion – carry out deficiencies pointed out.

REPONSIBILITIES OF CONTRACTOR, PROJECT ENGINEERS AND QA/QC CONSULTANTS.

• Shall maintain the Test Reports and make available for inspection and verification.

• Shall carry out corrective actions on the observation of Project Engineers and Consultants

• Shall preserve all the records as OK Cards, Site order Register, Test Reports till specific instructions are given by the Engineer – in - Charge

• Shall supervise the Construction activities• Shall provide approved construction drawing to

the Contractor before start of work. • Shall use only OK cards for recording all

observations before or during execution.• AEE / DEE / EE of both Construction and Quality

Control Divisions shall inspect and accord approval to start the work on OK Cards.

B. PROJECT ENGINEERS (Party – II)

• Project Engineers shall conduct independently Quality Tests using the contractor’s infrastructure.

• Officers shall inspect and record the observations / instructions in the Communication Register.

• All OK cards are initiated by Project Engineers which shall be preserved till the completion of work.

• Engineers shall verify the OK cards to ensure contractor's compliance to the corrective action before release of bill.

C. CONSULTANTS (PARTY – III)

• Will check the Work Programme and suggest suitable modification if needed and send it to the EE and the contractor.

• Shall inspect important work sites before work commences and record the observations in the OK card (such as foundations, reinforcement etc).

• During construction, conduct Quality Test to an extent of 10% and maintain the record. Shall witness 10% of the Tests conducted by the contractor. Before conducting Test shall inform project Engineers (Construction & Quality Control).

• Shall issue inspection note from time to time and record deficiencies in Communication Register and verify compliance there of .

• Shall organize pre – construction meeting with engineers of Department and Contractor and explain the preventive measures.

• On job training also shall be organized and issue training hand outs.

• Shall maintain Daily Activity Report, and submit to the Project Engineer.

• Shall review designs and drawings to ensure the construction is as per specifications

• Shall review the equipment available with the contractor and verity caliberation and testing personnel about adequacy as per agreement

• Shall conduct tests periodically on input materials

• Shall submit all documents to the EE, SE, CE and Project Director Periodically

• Shall also review the Contractor’s Resource Planning to cope with the work Programme.

GENERAL DEFICIENCIES – PREVENTIVE MEASURES.

A. Embankment :i) Inspection of borrow area – testing for suitabilityii) No over Wetting (not more than 2% of OMC)

iii) Over sized stones (more than 7.5 cm) be removed

iv) No roots and other unwanted material v) benching of slope while increasing the width vi) Sub-grade preparation-measured up to 15 to 25

cm vii) Proper spreading of soils in horizontal layers

(not more than 20 cm thick).

B. C C Lining :

i) Tested at Batching plant – Gravitational Measurement.ii) Fine aggregate should be hard, strong and clean.iii) Coarse aggregate should be free from unwanted material and should not be flaky and elongated.iv) Concrete should not be poured from a height.v) Curing

for 1 to 5 cu.m. 1 set (3 cubes)

6 to 15 cu. m. 2 sets

16 to 30 cu.m. 3sets

31 to 50 cu.m. 4 sets

and above 50 cu.m. additionally 1 set for every 50Cu.m.

VI) C C CUBES

for 1 to 5 cu.m. 1 set (3 cubes)

6 to 15 cu. m. 2 sets

16 to 30 cu.m. 3sets

31 to 50 cu.m. 4 sets

and above 50 cu.m. additionally 1 set for every 50Cu.m.

20 to 30 revolutions

3 or more cu. m….2 1/2 mts

2 cu.m . . . . . . . 2mts

1cu.m . . . .. . . . . 1 1/2mts.

VII) MIXING

REGISTERS FOR QA AND QC

1. Register of Bench Marks2. Mark out Register3. Material O.K. Register4. Register of Foundation5. Register of placement of Concrete

6 . Register of placement of Reinforcement7. Register for Embankment Placement (Roller Passes, Moisture Content, Proctor’s

Density etc.8. Site Order /Communication Register9. Cement Day Book.

THANK YOU

a) Registers:-1. Site order.2. Register of Bench Marks3. 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 specimens7. Cement day Book.

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.

• AE/AEEs have to check pre levels and final levels.

• For measurements recorded by E.P.C 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 E.P.C. 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 E.P.C. Agency and countersigned by the field Engineers.

• Under E.P.C. System of contract, fortnightly Management Meetings with E.P.C. Agency by the Superintending engineer shall invariably be convened to discuss the Quality Assurance Aspects and record the Minutes of Meeting regularly.

QUALITY CONTROL STAFF.

• Shall verify the records maintained at site by the E.P.C agency and the Third Party Quality Control Consultants.

• Shall check 25% of the final levels / measurements of Earth work, revetment, leveling, concrete, linear dimensions of important structures, Gates etc.

• Shall associate with construction staff or conduct independently the test with required frequency.

QUALITY CONSULTANTS

The Third Party Quality Assurance Consultants should posses all the testing facilities as per Agreement and conduct 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.

• Shall Submit Reports and Records to Engineer – in - charge

consultant to participate in designs review meeting with project engineers and contractors’ 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 DrawingsHPs, 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 EQUIPMENT

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

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 inspections, 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 and establish the contractors’ Q M P (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 efficiency 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.- Perusal 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.

MONITOR CONTRACTORS PROCEDURES FOR TESTING DEFICIENCIES TO ASSURE CORRECTIVE ACTIONS 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 RESULTSDepend on- Competency of the testing personnel- Accuracy of the apparatus and equipment- Maintaining special environment conditions- Proper maintenance and periodical

calibration of testing machines

PRE CONSTRUCTION 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 – ONGOING WORKS

To ensure the materials, construction works are as per specifications of APSS and IS codes.

Defect prevention is preferred to detection after occurrence.

QA CHECK – POST CONSTRUCTIONPhysical Measurements .

Identification of defects by both destructiveand non – destructive tests.

Classification of defects and rectification if necessary.

CONDUCT TESTS AT THE WORK SITE

Consultants to maintain confidentiality as regards the sample testing.

For reconciliation, the Engineer-in-Chargediscusses 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.