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Volume6
QualityAssurance&ControlofCivilWorks
PakistanPovertyAlleviationFund,Islamabad
TheRenewableEnergyGuidelineSerieshasbeendevelopedbytheGermanPakistanprojectDevelopmentof
Hydropower and Renewable Energy (HRE) in KhyberPakhtunkhwa, funded by German Development Bank
(KfW)onbehalfofMinistryforEconomicCooperationandDevelopment(BMZ).
PakistanPovertyAlleviationFund(PPAF)
Projectteam:
Mr.ZaarPervezSabri
SeniorGroupHead,PublicGoodsandServices
Mr.KamalAfridi
GeneralManager,Water,Energy&ClimateChange
Mr.ShaukatAli
RenewableEnergySpecialist
Contactaddress:
1HillViewRoad,Banigalla,Islamabad
PAKISTAN
Email:zaar@ppaf.org.pk
Phone:(+9251)261393550
NameofConsultants:
INTEGRATION
Team:
Dr.UlrichFringsTeamLeader
Mr.SherKhanDeputyTeamLeader
www.integration.org
Author:
ChristophSchmidt
Date:October,2013
CopyrightPakistanPovertyAlleviationFund2013
Reproductionisauthorizedprovidedthesourceisacknowledgedandprovidedareferencecopyisbeing
senttoPPAFandthereproductionisnotsold.
Forfurtherinformation:PakistanPovertyAlleviationFund,www.ppaf.org.pk
Note:Theinformationcontainedwithinthisdocumenthasbeendevelopedwithinaspecificscopeand
mightbeupdatedinthefuture.
PakistanPovertyAlleviationFund,Islamabad
Volume6
QA/QCManual
Guidelines&Manuals
Volume1:LifeCycleCostAnalysisinMHPPlanning
Volume2:CommunityContributionAspectsinRuralPowerSupplySystems
Volume3:GeneralDesignCriteriaonMHPs
Volume4:DesignAspectsofCommunityPVSystems
Volume5:Operation&MaintenanceAspectsofMHPs
Volume6:QualityAssurance&ControlofCivilWorks
Volume7:Health,Safety&EnvironmentalAspectsinCivilWorks
Volume8:Transmission&DistributioninRuralPowerSupplySystems
DesignSpecificationInstallation
Volume9:ElectroMechanicalEquipmentforMHPs
DesignSpecificationInstallation
Volume10:CommissioningGuidelinesPVMHP
Volume11:Micro/MiniHydropowerDesignAspects
Volume12:CivilWorksinRuralPowerSupplySystems
RenewableEnergyGuidelines Nov.2013 i
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TableofContents
1 Introduction................................................................................................................................4
2 Objectives...................................................................................................................................4
3 Communicationplan(Interaction).............................................................................................5
4 Duties,responsibilitiesandauthorityofQCpersonnel..............................................................5
4.1 Clientsrepresentative........................................................................................................5
4.2 POrepresentative...............................................................................................................6
4.3 Siteengineer.......................................................................................................................6
4.4 Contractorsprojectmanager.............................................................................................6
4.5 Contractorssiteengineer(s)...............................................................................................6
5 Design.........................................................................................................................................7
5.1 Background.........................................................................................................................7
5.2 Purposesofthisdesignqualitycontrolplan.......................................................................7
5.3 Subjectedtotheconditions................................................................................................7
5.4 Thecomponentsofdesignquality......................................................................................7
5.5 Mainstepsofqualityachievement.....................................................................................8
5.6 Designqualitycontrolmethodology...................................................................................8
6 Construction...............................................................................................................................9
6.1 Submittalproceduresandinitialsubmittalregister...........................................................9
6.2 Changesinapprovedsubmittals.......................................................................................10
7 Laboratorytestingformaterial................................................................................................11
7.1 Testingplanandlogs........................................................................................................11
7.2 Listofmaterialsundertestingsystem..............................................................................11
7.3 Materialmethodoftestingandfrequency......................................................................12
7.4 Routinematerialstesting..................................................................................................12
8 Completereworkitemsprocedures........................................................................................15
8.1 Responsibility....................................................................................................................15
8.2 Itemlist.............................................................................................................................15
8.3 Reworkprocedure............................................................................................................15
8.4 Preventiveaction..............................................................................................................16
9 Reporting..................................................................................................................................17
9.1 Responsibility....................................................................................................................17
9.2 Dailyinspectionreport......................................................................................................17
9.3 Monitoringandcontrolofworksprogram.......................................................................17
9.4 MonthlyQCreport............................................................................................................17
9.5 Testrecords.......................................................................................................................17
9.6 Sitedocumentcontrol......................................................................................................18
9.7 Qualityrecords..................................................................................................................18
9.8 Documentationstorage....................................................................................................18
10 Annexes....................................................................................................................................19
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Acronymsandabbreviations
1 Introduction
The successful implementation of projects is dependent on Quality control, which is vital to the
Constructionofinfrastructureprojects.Defectsorfailuresinconstructedfacilitiescanresultinlargecost
overrunsandleadtodelaysoftheimplementationschedule.Evenwithminordefects,reconstruction
may be required and facility operations impaired and delayed. In the worst case, failures may cause
personal injuries or fatalities. Sound project management of the Program supported by a thorough
QualityControlSystem(QCS)ensuresthattheworkiscarriedoutprofessionallywithvalueengineering.
For the efficiency of the Quality Control Project Management it will be necessary to have a fair and
transparentmechanismwithclearcommunicationandinstructionsonsite.
The quality system described in this project quality plan (QCM) shall form the core activities and
processestobeutilizedtomonitorandcontrolthroughoutthesuccessofthisproject.
TheQualityControlPlancomprises:
The Site Engineer will maintain an adequate inspection system and perform inspections that will
ensureagreementcompliance.
TheSiteEngineerwillmaintaininspectionrecordsandmakethemavailabletotheclient.
The Site Engineer will allow the client to do its own tests and inspections and requires the
implementertoassist.
TheSiteEngineerfollowuptestsandinspectionswillbeforitsbenefitofprojectdeliverables.The
qualitycontrolobligationsinthetestingandinspectionremainindependentandunchanged.
TheSiteEngineertoassisttheclient(owner)inensuringcompletionofthisprojectwithinthestated
timeline,budgetandquality.
TheSiteEngineertoprovidequalitydesignmanagementandconstructionmanagementservicesthat
consistentlymeetsclients'statutoryandregulatoryrequirements.
TheSiteEngineertoberesponsiveinimplementinggoodengineeringpracticestoeliminatepotential
qualitydeficiencies.
TheSiteEngineercontinuouslytoimproveallfunctionswithintheprojectteamincooperationwith
theclientthroughinnovationandcreativity.
2 Objectives
With a clear concise and manageable quality system each member of the Construction Supervision
Teamcanensurethatithasplayeditspartinthesuccessandvalueoftheproject.Proceduresthathave
been closely followed will ensure that the Employer/Client is confidently receiving a cost effective
qualityproductinatimelymanner.
It is vital that the quality system is reviewed regularly in order to revise procedures when necessary
and/or required. Suggestions for improvements in procedure changes and revisions from all parties
involvedintheProgramarenecessary.
This quality control plan does not endeavor to repeat or summarize agreement requirements. It
describes the process that the PO will use to assure compliance with those requirements. The
agreementisthefoundationfortheoutcomesexpectedfromthequalitycontrolplan.
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3 Communicationplan(Interaction)
In order to have thorough and clear communication at all times between all involved partners Site
Engineershallcoordinate:
All construction documents as there are Drawings, BoQ, Specifications, Submittals, Test reports,
Inspectionreports,Daily,WeeklyandMonthlyReports,Safetyreportswillbeavailable,maintained
andstoredinSiteEngineerofficeforreview.
SiteEngineerwillbepermanentlyonsiteandcarryoutinspectionsduringconstructionondailybasis.
Site Engineer shall constantly coordinate/liaise with the Client and Contractor during pre
construction(sitepreparations),construction,andpostconstructionprojectcycle
RoutinejointinspectionwithClient,SiteEngineerwilldocumenttheactualstatusoftheprojectto
ensurethatworkactivitiesinthesitehavebeendoneinaccordancetothecontract.Agreementon
observationswillbenotedandenteredinseparatedailyinspectionreports
Client Engineer shall ensure that the quality control is applied in accordance to Quality control
procedures
Client Engineer will conduct inspection independently with contractors representative and write
notificationindailyinspectionreport
ClientandSiteEngineerwillreachconsensusonmethodsofinspectionandtestingaccordingtothe
specificationsinaccordancetoQCM.
ClientandSiteEngineerwillagreeonthesizeoftheconstructiontaskthatitsmaterialsrequiretobe
testedinaccordancewiththeTechnicalSpecificationsandQCM.Followupjointwitnessinspections
intestlaboratorybyClientandSiteEngineerismandatory
ClientandSiteEngineerwillreachconsensusondefectrectificationrequirementsandwillbenoted
inseparatedefectlog/reports.
ClientandSiteEngineerwillbeboundtorectifyallsuchdefectsandtonotifythecontractortotake
immediateactioninaccordancewithReworksectionofthisManual.
IncaseofanydifferencesondefectsbetweenClientandSiteEngineer,thematterwillbeforwarded
totheheadoffice.
If the disagreement is not resolved between Client and Site Engineer and feels that the issue is
serious and needs special attention, the problem should be brought to attention to the JV back
stoppingteamforfurtherexpertize.
ClientandSiteEngineerwillupdatetheirQCandQAreportsondailybasisandoldissueswillnotbe
repeatedafterrectificationsmeasuresaretakenandclosed.
Client and Site Engineer will conduct weekly QC meetings on site. Minutes of meetings have to be
preparedbySiteEngineer.
4 Duties,responsibilitiesandauthorityofQCpersonnel
4.1 Clientsrepresentative
TheClient,representedbytheSiteEngineerisresponsibleandaccountablefortheimplementationof
all activities. The Client will facilitate the efforts of the design and construction projects. The PM will
facilitatetheeffortsofthedesignandconstructionteamsinacoherentandefficientmannerandwillbe
ultimatelyresponsibleforensuringtheobjectsofthePOandPPAFasdescribedintheagreementand
supportingdocumentation.
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4.2 POrepresentative
Site Engineer is directly supervising and monitoring to assure the construction quality control system.
Site Engineer will report directly on a daytoday basis regarding the progress of the works. Site
EngineersQualityControlteamensuresthattheProgramQualityManagementandSafetySystemare
being implemented according to the requirements of the PO. The Site Engineer oversees all technical
aspects in the specified technical area of work including but not limited to assessment, design, Bill of
Quantities(BOQ)calculation,tendering,technicalspecification,andmonitoring.
4.3 Siteengineer
The Site Engineer is responsible for the directly supervision of contractors site engineers including
contractors QC engineers. Provide field project control support by identifying, monitoring, project
related issues, impacts and resolution. Directly liaise with contractors and Client when necessary and
directlyreporttotheClientfortechnicaladvice,supportandfieldresolutionwhennecessary.TheSite
Engineer oversees all technical aspects of infrastructure project implementation work in the specified
technical area of work including but not limited to assessment, design, Bill of Quantities (BOQ),
calculation,tendering,technicalspecification,and monitoring. TheSite Engineerisresponsibleforthe
designintegrity,professionaldesignstandardsandallservicesrequiredbytheagreement.Furthermore
for the development of design quality control plan, incorporation and maintenance for the approved
design schedule. Site Engineers shall be responsible for ensuring that all designs, specifications and
BOQs produced for this award are in accordance with the requirements identified herein. The Site
Engineer will be responsible to implement and manage the quality control program. In addition to
implementing and managing the quality control program, the Site Engineer is required to perform
submittal review and approval, ensure testing is performed and provide QC certification and
documentation as required in the agreement. The Site Engineer is responsible for managing the
coordinatingpersonnelrequiredbytheagreement.
4.4 Contractorsprojectmanager
The contractor has based on the contract agreement to assign a Project Manager with required
qualifications and skills to ensure the completion of the infrastructure project successful according to
the approved implementation schedule in quality and quantity. He is overseeing the work of the site
engineers. The PM will guarantee QCM standards are performed, and prepare QC certifications and
documentationrequiredbytheagreement.
ThePMshallbeontheconstructionsiteduringanyshiftswhenconstructionworkisperformed.Duties
and responsibilities according to the QCM are not limited to the contract agreement between the
EmployerandContractor.
4.5 Contractorssiteengineer(s)
Site engineers oversees the whole construction process and shall assist the PM in processing and
maintaining files for submittals, preparing and publishing reports, and meeting minutes. The Site
Engineer is responsible to ensure the quality and quantity of the work based on the Design and
Technical Specifications. He has to manage all processes on site, will be responsible for the material
planningandtimelyprovision,theplanningofworkforcetoensuretheprojectimplementationintime,
qualityandquantity.ThesiteengineerisempoweredbythePMtosuspendconstructionactivitieswhile
deficienciesarecorrectedaftertheClientandClientsRepresentativeareinformed.Therewillbeatleast
one site engineer per site but not limited if necessary and/or requested by the client or clients
representative. Duties and responsibilities according to the QCM are not limited to the contract
agreementbetweentheEmployerandContractor.
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5 Design
5.1 Background
Considering the limited resources in Pakistan, considering the social and economic conditions and
aiming to produce and present the highest yield, quality control and quality assurance are gaining
considerablylargeimportance.
5.2 Purposesofthisdesignqualitycontrolplan
Maximizetheuseoflocalmaterials
Maximizetheuseoflocalmenpower
Achievethemaximumpossibleyieldfromavailableresources
5.3 Subjectedtotheconditions
Safety,durability,comfortandaestheticalrequirementsofuniversallyacceptedstandardsandcodes
suchasDINEN,ASCE,IBCorequivalentarefulfilled
Thetechnologyproposedcouldbeappliedinthelocation
Thetechnologyproposedistutorialandeducativetolocalpeople
5.4 Thecomponentsofdesignquality
5.4.1 Properteam
TheDesignCompany/ContractorwhichisresponsibleforDesignQCwillprovideoremployprofessional
peoplewhohavegoodtrainingandhaveexperienceindevelopingdesigns.Allmattersconcerningthe
qualitycontroloftheprojectwillbereportedinwrittentotheClientandSiteEngineer.
5.4.2 ProperUtilities
TheDesignCompany/ContractorwillprovideproperequipmentanddependablesoftwareforAnalysis,
DesignandComputerAidedDrawings.
5.4.3 Adequatetraining
The Design Company/ Contractor that will have contributions to the designs will be trained about
internationallyacceptedanduseddesignstechniquesandconstructionsystems.
5.4.4 Codesandstandards
Confirmationofthedesignstothefollowingcodesandstandardswillbeachievedby:
Trainingofteam
Spontaneouschecksduringallphasesofdesigning
Bypreparationofcodeconfirmationreportsatthemilestonesofthedesignschedule.
5.4.5 Thegoverningcodesinqualitycontrol
IBC,InternationalBuildingCode
ACI,AmericanConcreteInstituteCode
NFPA,NationalFireProtectionAssociationCode
UFAS,UniformFederalAccessibilityStandards
ADAStandardsofAccessibilityDesign,DepartmentofJustice
ASTM,ACI
ConstructionStandardIndex
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5.5 Mainstepsofqualityachievement
ClearunderstandingoftherequirementsoftheClient
Developing and proposing a satisfactory architectural preliminary that satisfies the code
requirements
Thegeographic&climaticrequirements
Thecostefficiencyrequirementsaresatisfactorily
PresentationoftheabovetotheClienttogetherwithcodeanalysisreport.
AchievingapprovaloftheClient
Selection of design criteria for application project, selection of materials of construction,
technologies.
ReportingtotheClienttogetherwithpossiblealternatives.
AchievingfinalapprovaloftheClient
FinalizingArchitecturalDesignsaccordingtocommentsoftheClientandSiteEngineer
Achievingapprovaloftheclient
Developing Structural, Mechanical, Electrical designs considering the seismic, dynamic, live load
evaluations, permissible or ultimate stresses, alternate loadings possible, heat and electric energy
requirements,applicablecodesandtechnologies.
PresentingandReportingthedesignsandcalculationstotheClient,accompaniedbycodeanalysis.
Achievingapprovaloftheclient
Preparingquantitativecalculationsfortendering(BoQ)
Preparing Technical Specifications (TS) to achieve desired quality and to enable correct cost
estimationofbiddersandtoavoidfuturedisputes
5.6 Designqualitycontrolmethodology
Anetworkthatisaccessibletoalldesignerswillbeestablishedandalldailyworkswillbestoredtoa
commonareainthisnetworkattheendofeachworkingday.
ArchitectsandEngineerswillproceedaccordingtotheitemslistedinthechecklistsaspresentedon
Annexes and at the start of each activity will prepare a list of particulars of the requirement (e.g.
mainrequirementofclientortask,codestobefollowed,minormaximumsizerequirementsetc.).
TheEngineerofRecordwillexaminethereport,willinvitetheotherengineersorarchitectsfortheir
commentsifthetaskrequiresadditionalinformationfromdifferentdisciplinesetc.andwillapprove
thereporttogetherwithhis/heradditionalcomments.
Afterachievingthementionedapprovalthedesignerwillproceed.Thedesignerwillprovideacode
confirmationlistassoonashecompletesthedesign.
Thedesignteamwillhaveonequalitycontrolmeetingeveryweekandwilldiscussthepartsofthe
designsthatwereproducedintheprecedingweekandallcommentswillberecordedandminutes
willbeprovidedtotheClientandSiteEngineer
Aftercompletionofaspecificdesignthecompletedesignteamwillmakeafinalreviewofthework
andcheckwhetheritfulfillsalltherequirementsoftheclient,checklistsofthisQCplan,thecodes
etc.
Itisimpossibleforadesigntoremain100%unchangedduringtheprojectlifecycle.Consideringthis
factorofdesignchanges,aspreadsheethastobeproducedtohighlightwherechangeshavebeen
madeandtowhichdrawingsandsitestheyapply.
AnyfielddesignchangeswillbebroughttoacknowledgementanddiscussedwiththeClientandSite
Engineer so that the reasons of the request will be clearly understood and negotiated. In case
required,theclientwillbeinformedaboutthedesignchangesaccompanyingareportexplainingthe
reasons,effectsonprojectandfinancialrequirementsandpossiblytimescheduleeffectsofit.
Afterapprovaloftherequestthedesignswillberevisedandwillbesubmittedtotheclientforthe
finalapproval.
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6 Construction
6.1 Submittalproceduresandinitialsubmittalregister
SiteEngineerwilladministerandcontroltheprocessingofcontractorssubmittals.Afterbeingreviewed
forcompleteness,submittaldocumentswillbetransmittedtotherelevantstaffinDesignDepartment
forreviewandverificationforcompliancewithcontractrequirements.Submittaldocumentsneedtobe
approvedfinallybytheClient.
IncaseofDesign/Buildcontractsthesubmittaldocumentscanbepreparedincompliancebetweenthe
design and construction department of the contractor but have to be finally approved by the design
department.
6.1.1 Submittalregister
Thecontractorwillsubmitandmaintainasubmittalschedule.TheSiteEngineerwillreviewtheschedule
inaccordancewiththeconstructionprogressschedule.
Thedetailedprogressschedulewillbeinitiallysubmittedwithin14daysaftertheawardofthecontract
and may be updated as required or after application of the contractor. If any changes apply the
contractorneedtheapprovalbytheClientorClientsRepresentatives.
Site Engineer will maintain a completed submittal schedule and list of products for all items requiring
Clientsreviewandapproval,asfollows:
Submittals, including description of the item and the name of the manufacturer, trade name and
modelnumber
SpecificationandBoQreference
Intendedsubmission/resubmissiondate(s)
Leadtimetodelivery/anticipateddeliverydate(s)
Highlightinganyitemsthatrequireexpeditedreviewtomeettheprojectschedule
IdentifywhichsubmittalsrequireClientsand/orSiteEngineersapproval
Theseschedulesshallbepresentedintheattachedforminbothelectronicandhardcopyversionand
shallbeupdatedandsenttotheClientsand/orSiteEngineersonaminimummonthlybasis.
6.1.2 Reviewperiod
Contractor will insure that Submittals will be prepared sufficiently in advance so that review and
approval by the Site Engineer in coordination with the Client will be given before commencement of
related work. The contractor is responsible for the preparation of Submittals according to the time
scheduleto avoiddelays.Ifthereany delaysapply dueto contractorsfaultpenaltiesaccording tothe
contractwillapply.
Incaselongerreviewandapprovalperiodsarerequired,SiteEngineerandthecontractorshallschedule
workaccordinglytoavoidthatprogressschedulesarenotadverselyimpacted.
6.1.3 Submittalreviewers
TheContractorshastofilloutandcompletesubmittalformsandtosubmitinpaperformandone
electroniccopyofallrequiredsubmittalstotheSiteEngineer
SiteEngineerhastoreviewthesubmittaldocumentstoascertainwhetherthepackageiscomplete.If
submittalisincompletethesubmittalwillbereturnedtothecontractor.
ThecompletesubmittaldocumentsandallcopiedattachmentswillbestoredinClientEngineersdata
baseandwillbeforwardedtotheappropriatereviewerintheDesignDepartment
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TheDesignteamwillreviewthesubmittaldocumentsincompliancewiththecontractspecification
andagreementandreturntotheSiteEngineerwithcommentsandapproval
Site Engineer in accordance with the Client and will return the submittal to the contractor with a
decision
The Client reserve the right that submittal reviewers other than the Site Engineer, qualified in the
disciplineswillreviewandcertifythatthesubmittalsmeettherequirementsofthisagreementprior
tocertificationorapprovalbytheSiteEngineer
The contractors PM and/or site engineers and design engineers will be authorized to review and
certifysubmittalspriortoapprovalbytheSiteEngineerbutitappliesthatthefinaldecisionwillbe
takenbytheClient
6.2 Changesinapprovedsubmittals
Changesinapprovedsubmittalswillnotbeallowedunlessthoseapprovedsubmittalswithchangeshave
beenresubmittedandapprovedaswritteninclause6.1.
6.2.1 Supplementalsubmittals
Supplemental submittals initiated by the contractors for consideration of corrective procedures shall
containsufficientdataforreview.Supplementalsubmittalswillbemadeinthesamemannerasinitial
submittals.
6.2.2 Engineeringreview
SubmittalswillbereviewedforconformancewiththeTechnicalSpecifications,BoQandthecontract
agreement.
Thereviewofaseparateitemwillnotconstitutenecessarilythereviewofanassemblyinwhichthe
itemfunctions.
Thereviewer,Designer,Contractor,SiteEngineer,willindicateitsreviewsofthesubmittalandthe
actiontaken(approvalsandnonapprovals),signedanddatedandsubmittedtotheClientand
Reviewactionswillhavethefollowingmeanings:
o Approved:isanacceptance
o Submittal appears to conform to the respective requirements of the specifications and
agreement
o Fabrication,assembly,manufacture,installation,application,anderectionoftheillustratedand
describedproductmayproceed;andthatthesubmittalnotneedberesubmitted
o Disapproved:isanonacceptance
o Meansthatthesubmittalisdeficienttothedegreethatthereviewercannotmakeathorough
reviewofthesubmittal
o Thesubmittalneedsrevision,andistobecorrectedandresubmitted.
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7 Laboratorytestingformaterial
If required the Client and Site Engineer reserves the right the contractor has to contract materials
testinglaboratoriesforeachjobsite,foronsitetestingandoffsitetesting.Theselectedlaboratoryfor
eachlocationneedstobeapprovedbytheClientandSiteEngineer.
7.1 Testingplanandlogs
Astestsareperformed,theContractorsPMorSiteEngineershallrecordontheTestingPlanandLog
thedatethetestwasperformedandthedatethetestresultswereforwardedtotheSiteEngineer.The
SiteEngineerhastosubmitalltestresultstotheClient.AcopyofthefinalTestingPlanandLogshall
beprovidedintheOperationsandMaintenancesupportdocumentation.
Ifrequiredmaterialsqualificationtestingwillbedonepriortoconstructiontoverifythatthematerials
comply with requirements of the Contract Agreement, the Technical Specifications and BoQ. The
contractorwillobtainrepresentativesamplesofthematerialsdesignatedastheproposedsourceofthe
materials.Testsampleswillbesentbythecontractortotheapprovedtestinglaboratories.Thetesting
laboratory will report all test results for determination of materials quality. The testing will be
performedbythelaboratory,thecontractorandmonitoredbytheSiteEngineer.
TheClientwillperiodicallyinspectthematerialbeingused.Ifdeterminedthatthecharacteristicsofthe
materialbeinguseddifferfromthematerialinitiallytestedordesigned,thecontractorhastorepeatthe
qualification testing. If the new material qualification test results meet the criteria of the technical
specification as determined, the materials may be used for the work, otherwise, previously approved
materialsmustbeusedorotheracceptablematerialsmustbesampledandtestedasnotedbeforeprior
toincorporatingintothework.
7.2 Listofmaterialsundertestingsystem
The below stated list of material is for sampling and not completed. The Client, and Site Engineer
reservetherighttorequiretestsformaterialadditionaltothematerialsasstatedbelow:
Cement
Concrete
Asphalt
Mortar
Aggregates
Reinforcementsteel
Wires
Plaster
ElectricalMaterial
PlumbingMaterial
SanitaryMaterial
GuardRails
Signs
PPE
Wood
ShutteringMaterials
Othersnecessary(refertotechnicalspecification,BOQandTechnicaldrawingsrecommendations)
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AllitemsforconstructionshallbecoveredundertheContractAgreement,theTechnicalSpecifications
andBoQandshallmeetIBCStandards.Ifrequiredsomeoftheitemsshallbeprovidedassampleswhich
thecontractormustproduce/purchasetothesamestandard.
7.3 Materialmethodoftestingandfrequency
All quality assurance testing will be conducted in accordance with Project Specifications, the Contract
Agreement, Technical Specifications and BoQ or in accordance with an individual project construction
plan. The Site Engineer will observe all applicable testing methods, as previously identified. The
documentationandreportingoftestresultswillbeincludedwiththedailyconstructionQCreportand
enteredintoQCsystem.
AlltestresultshavetobeupdatedandfiledseparatelyandifrequiredtobepresentedtotheClient.
Alltestsshallbecarriedoutinaccordancewithinternationalcodesand/orspecifications.
7.4 Routinematerialstesting
The Site Engineers will routinely inspect and verify that labels, tags, manifests or the identifying
documentsofallconstructionmaterialsconformtotheapprovedmaterialspecifications.
The Site Engineers will also monitor testing of components and equipment to ensure that tests and
resultsconformtointendedcriteria.
TheSiteEngineersreservetherighttobepresenttowitnesstestingandobserveconstructedfeatures
beforebeingcoveredorobscuredbysubsequentconstructionactivities.
Alldailyroutineinspections,testingmonitoring,andindependenttestingperformingpersonnelwillbe
recorded and entered into the QC system and will be available to be viewed by the Site Engineers as
required.
Site Engineer shall develop material testing procedure based on construction progress schedule and
quantitiesaccordingtoplans,specifications,andothercontractdocumentsforeverydefinablefeature
ofworkincludeactivity,samplingfrequency,date,numberofsamples,andlocationoftest.
Belowstatedtableneedstobeadjustedaccordingtotheprojectspecificationsandrequiredstandards
inthedesign.
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AggregateConcrete
Gradation,salt,harmful ASTMC33&C330 Onesampleatsourcepriorto Insurephysicalrequirementof
materials commencementofwork coarse&fineaggregate.Absence
Asper318Sec.3.3 ofharmfulsubstances
Grout
MinimumCompressive ASTMC1019 Preliminarytestingofmixdesign. (i)CompressivestrengthforMTC
Strength Testonceonadailybasisduring projectremainatleast13.8
groutingoperations. MPa)@28days
Compressivestrengthatleast
3000psi(21MPa)@28days
CementMortar
TypeMand/orS ASTMC27008a Masonrycementmortar(pre TypeM:CompressiveStrength(
Cement BuildingCode packaged). 17.2MPa)2500PSI@28days.
Requirementsfor MixRatio:
MasonryStructures Correctproportionofsand&water (ii)TypeS:CompressiveStrength
Table2.2.3.2,Table tomeetACI530.08min.required 1800psi(12.4MPa)@28days
3.1.8.2,Table5.4.2 strength.
Ref.MixRatioforTypeM&S(refer:
QC/SITE/7)
MasonryBlock
Compressivestrength& Sampledandtestedin Preliminarytestof3samplesof UnitconformstoASTMC90.
dimensions accordancewithASTM concreteblocksdeliveredonsite ASTMdonotrequireddesign
C140 standard.Onlyhelpassure
compliancewiththedesign.
Compressivestrengthandnot
lessthanof1500psi
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8 Completereworkitemsprocedures
AnyindicationofsystemdeficiencieswhetherdiscoveredasaresultoftheClient,SiteEngineerand/or
the Contractor/Designer checks and tests, will result in modifications to the system to correct these
deficiencies.
The contractor shall be notified by the Site Engineer in writing when deficiency is discover and shall
immediatelystopwork,oruseofthedeficiencymaterialsandshallrepair/replaceorcorrectdeficiency
beforeworkcontinue.TheClienthastobeinformedinwritten.
IfanydisputethecontractorshallsubmitinwritingforClientandSiteEngineer.
Ifthecontractorbelievesasuitablerepairispossible,executedattheirexpenses,theContractorhasto
prepareaplantoaffectrepairorcorrectionandsubmitfortheClient,SiteEngineerforapproval.
For the purpose of this manual, deficiency shall be any variation from the plan or specification that
result in lower quality of work, reduce useful life circle of work and impair functionality of work and
unsafe condition, or materials change in the appearance than is deemed by the Site Engineer to be
unsatisfactoryandtorequirefulfillmentaccordingtotheContractAgreement,TechnicalSpecifications
andBoQ.
8.1 Responsibility
ItistheresponsibilityoftheSiteEngineertoensureidentifiedconstructiondefectsarecorrectedina
timelymanner.AlsodefectsidentifiedbyClientandSiteEngineerwillbenotedandrectifiedinatimely
manner.
8.2 Itemlist
The Site Engineer will maintain a list of work that does not comply with the construction plans and
TechnicalSpecificationsContractAgreementandBoQ
Identification,whatitemsneedstobereworked
Thedatetheitemwasoriginallydiscovered
Thedatetheitemwascorrected
Anitemthatiscorrectedonthesamedayitisdiscoveredwillnotbereportedinthislog,butinthedaily
qualitycontrolreport.
8.3 Reworkprocedure
When executed work, materials, or installations are found in non compliance with Technical
Specifications and/or drawings, the Contractors PM and Site Engineer under supervision of the Site
Engineershallensurethatnonconformingmaterials,work,orinstallationareidentifiedandcontrolled
storageandseparatedtopreventunintendeduseordelivery.
The Site Engineer will notify the contractor of any noncompliance. After receipt such notice, the
contractorshalltakeimmediatelycorrectiveaction.
Major deviations from the contract requirement and/or quality are nonconformance and must be
formallydocumentedforcorrectiveactionbytheContractor.Anonconformancereportmustbeissued
tothecontractorforcorrectiveactiontobetakenwithin3workingdays.
If the Contractor fails to correct a minor deficiency after 5 days of the notice, it will result in a non
conformanceandbeenformallydocumented.
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Ifthecontractorfailstotakecorrectiveactionregardingnonconformancewithinthespecifiedperiodof
time,aStopWorkOrderwillbeissuedtothecontractor.
Relatedorcontinuingactivitiesorconstructionshallbestoppeduntiltherectificationanydeficiencies
thatarecriticaltotheintegrityofthestructureorthefacilityandorsafetyofpublic.
Ifpossible,thisstopworkorderwillonlyaffectthedefective,deficientorunsafework(areas)andthe
contractormaycontinuewithanyorallotherprojectwork.
AfterissuingtheStopWorkOrder,orifpossibleinadvance,theSiteEngineerhastoinformtheClientto
helpsolvetheissueswithcontractorsmanagement.
8.4 Preventiveaction
Preventive actions will be taken to eliminate any cause or potential nonconformity. Continuous
preventionmeasuresarepermanentlyneededtoavoidoccurrenceofdeficiencies.
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9 Reporting
9.1 Responsibility
TheContractorsPMandsiteengineerwillmaintaincurrentandcompleterecordsofonsiteandoffsite
qualitycontrolprojectoperationsandactivities.
SiteEngineerwillmaintainasecondcopyofallthequalitycontrolrecordsinsiteofficeandguarantee
theunlimitedaccessthroughtheClient.
Site Engineer is responsible for reviewing and approving Contractors PM and/or Site Engineers daily,
weeklyandmonthlyconstructionmonitoringreport.
ContractorsPMand/orSiteEngineersareresponsibleforsubmitting3weekslookaheadworkplanand
weeklyperformance.
9.2 Dailyinspectionreport
QCinspectionreports,providedbytheSiteEngineer,willbesubmitteddailyandwillaccountforeach
calendardaythroughoutthelifecycleoftheproject.
TheSiteEngineershallreview,commentandapprovethedailyreportspresentedbythecontractor.
Reportswillincludepertinentinformationincluding directionsreceived,problemsencounteredduring
construction, work progress, safety hazards encountered, instructions given and corrective actions
taken,delaysencountered,arecordofvisitorstotheworksite,qualitycontrolproblemareas,weather
condition, photos, deviations from the QC plan, construction deficiencies encountered, and record of
meetingsheld.
9.3 Monitoringandcontrolofworksprogram
TheSiteEngineerteamshallundertakeregularreviewoftheContractorsOverallWorksProgramsothat
itshallbeinlinewiththeapprovedMasterImplementationPlan(baselineprogrammed).CriticalPath
Analysis shall be performed to identify critical activities. The Site Engineer would work with the
contractortomitigateanydelaystokeeptheprojectonschedule.QCandsiteengineersshallsubmit
weeklyperformance/productivityScurvecharttogetherwith3weekslookaheadprogrammed
9.4 MonthlyQCreport
The monthly progress report shall contain overall progress of work plan activities reported for the
current month. Financial progress, milestones key dates, accomplishments, bottlenecks, materials
certifications,testsperformed,QCdeficienciescorrected.
9.5 Testrecords
AlltestingactivitieswillberecordedontherelevantconstructionQCReport,indicatingthenameand
number of tests performed, specification paragraph reference, and location performed, and will be
enteredintocomputerizedQCtrackingsystem.Testresultswillberecordedonthedailyconstruction
QCreportorattachmentsandenteredinQCsystem.Actualtestreportswillbefurnishedpromptlyto
thePOorasdirectedbythespecification.
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9.6 Sitedocumentcontrol
TheDocumentController(Administrationsupportstaff)shallimplementtheProjectQualitySystemto
control the identification, numbering, modification, approval, distribution and filing of all documents,
dataanddrawings.
Thechecking,approval,identificationanddistributionofthedocumentanddrawingsareasindicatedin
the Project Quality System Procedure (PQSP). Each document shall be assigned a unique number in
accordancewithstandardnumberingprocedures.
9.7 Qualityrecords
Thequalityrecordstobemaintainedandkeptfortheprogramareasfollows:
InspectionRecords
MethodStatements
Nonconformancesandcorrectiveactionreports
QCplanandAuditreports
Testrecords,certificates,warrantiesandguarantee
Client,ContractorsandConsultantProgressReport
Contractors&ConsultantMonthlyPaymentReport
Incoming&OutgoingCorrespondence
TechnicalDrawing,ShopDrawingandAsbuiltDrawing
DocumentRegisterLog
Designdocumentrecords
Tenderdocumentrecords
Constructiondocumentrecords
Otherdocumentsnecessary
9.8 Documentationstorage
QCmanagementteamshallmaintainallconstructionrelateddocumentandsubmittalsinacombination
ofasecureedocumentfilingandstoragesystem.Thecomputerizeddocumentcontroltrackingsystem
shallbeachievedinPOsnetworkserver.InternalprojectQCauditshallconductatrandominternalon
thedocumentcontrolssystemwhennecessary.
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10 Annexes
Annex1: Dailyprogresreport......................................................................................................20
Annex2: Weeklyprogressreport.................................................................................................24
Annex3: Requestfortesting(RFT)...............................................................................................27
Annex4: Requestforsurvey(RFS)...............................................................................................29
Annex5: Requestforinspection(RFIP)........................................................................................31
Annex6: Nonconformancereport..............................................................................................33
Annex7: Requestforaudittesting...............................................................................................35
Annex8: Requestforauditsurvey(RFS).......................................................................................37
Annex 9: Requestforinformation............................................................................................39
Annex10: Designchecklist.........................................................................................................40
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Annex1: Dailyprogressreport
DPR Date
Site No.
Project Title
Location Province
Coordinates
Contractor
Date of Contract Signature
Date of Construction Start
Date of Completion (Contract)
New Completion Date (Time
Amendment)
Percentage of Project Complete
Is project on schedule Y/N
Reported by
1. Personnel on Site:
Contractor Super Enginee Fore Skilled Unskille Operators Others
visor r man Labor d Labor
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3. Supplied Material:
4. Work Progress :
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8. Design Issues:
Date No. Issued by Issued to Description Date of
rectificatio
n
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12. Visitors
Visitor Reason for visit Comments
13. Pictures:
Please insert pictures documenting activities and defects and describe when necessary, the
number of photos is not limited
PHOTO PHOTO
PHOTO PHOTO
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Annex2: Weeklyprogressreport
Report
WPR Date 2014-MM-DD DDth to DDth of MM. YY
Period
Site No.
Project Title
Location Province
Contractor
Date of Contract Signature
Date of Construction Start
Date of Completion (Contract)
New Completion Date (Time
Amendment)
Percentage of Project Complete
Is project on schedule?
Reported by
1. Labour on site:
Day
2. Equipment on site:
Day
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4. Instructions:
Occasion Instructions to contractor/ subcontractor/ supplier Date of
rectification
5. Design Issues:
Date No. Issued by Issued to Description Date of
rectification
7. Other Discussions:
With Day Discussed Comments
8. Visitors:
Visitors Day Reason for visit Comments
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9. Pictures:
Please insert pictures documenting activities and defects and describe when necessary
(photos have to be compressed) 10-20 photos
Photo Photo
Photo Photo
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Annex3: Requestfortesting(RFT)
Project No.:
Project Name:
Contractor:
Embankment (Layer)
Embankment Top (Layer) Stone Masonry Work
Base Course (Layer) Culvert
Structural Concrete Material Source
Others
Location: Km ______________________ to Km
________________________
tests: ______
_____________________
Contractors comment/Description:
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Annex4: Requestforsurvey(RFS)
Project No.:
Project Name:
Contractor:
_____________________
Location: Km ______________________ to Km
____________________________
Chainage/Station Offset (m)
_____________________
Contractors comment/Description:
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submit
(day/month/year)
(day/month/year)
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Annex5: Requestforinspection(RFIP)
Project No.:
Project Name:
Contractor:
Location: Km ______________________ to Km
________________________
_____________________
Contractors comment/Description:
_________________(day/month/year)
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Annex6: Nonconformancereport
Project No.:
Project Name:
Contractor:
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Name: Signature:
Date:
Contractors QC Manager/Representative
Name: Signature:
Date:
Name: Signature:
Date:
Name: Signature:
Date:
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Annex7: Requestforaudittesting
Project No.:
Project Name:
Contractor:
(Lab) Comments/Recommendations:
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Engineers Comments:
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Annex8: Requestforauditsurvey(RFS)
Project No.:
Project Name:
Contractor:
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Engineers Comments:
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Annex 9: Requestforinformation
Project No.:
Project Name:
Contractor:
(i) Issues:
(ii) Impact:
(iii) Recommendations by
1. Design
2. Construction
By: 3. Cost Impact
Date: 4. Extension of Time
Signed by:
Site Engineer:_______________________Date: ______________(day/month/year)
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Annex10: Designchecklist
Project No.:
Project Name:
Contractor:
Date
Project Title
Province
Specific Location
Client
ARCHITECTURAL REVIEW Yes No Remarks
Have all previous design comments been answered?
Do the drawings comply with the BoQ?
Do the drawings comply with the technical specifications?
Have the designs been coordinated with Structural Engineers?
Have the designs been coordinated with Electrical Engineers?
Have the designs been coordinated with Mechanical Engineers?
Are title blocks labeled correctly?
Are relevant calculations submitted?
Are the drawings updated on the drawing register?
PO PM Signature Date
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YES NO
Reviewed by
Approved by
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