PM Project Quality Plan 8-7-2012

Al Fowriya Trading &
Project Quality Plan Contracting
Al Fowriya Trading & Contracting W.L.L.

P.O. Box: 24110, Doha-Qatar
Tel: 44425874 / 44212047, Fax: 44429027
Project Quality Plan
Project: CONSTRUCTION OF NEW SECURITY GATE HOUSE AND

ADMINISTRATION BUILDING IN QP REFINERY AT MESAIEED
Client: M/s. Qatar Petroleum
Ref. No.
REV.0 Date: 09.06.12
GC10109300/MS/001
Prepared By Checked By Approved By
QA/QC Engr FTC Project Manager FTC QP EDM
S No SECTION PAGE
01 Introduction 05
02 Project Scope 05
03 Project Quality Statement 06
04 Revision Status / Amendments 06
05 Definitions and Terminology 07 08
06 Quality Policy, Quality System & Quality Strategy 09 13
6.1 Quality Policy Concept
6.1.1 Quality Policy
6.1.2 Quality System
6.1.3 Structure of Quality management system
documentation
6.1.4 Hierarchy of the documentation
6.1.5 Quality Management System manual
6.1.6 Quality Process & procedure manual
6.1.7 Project Quality Plan
6.1.8 Other Quality document
6.1.9 Quality Strategy
6.2 Planning
6.3 Control
6.4 Verifications
07 Quality Management in Construction and Reporting. 14 23
7.1 Management Responsibility
7.2 Organization set up for the Project
7.3 Job Responsibility matrix.
7.4 Responsibilities & Authorities
7.5 Functions of QA / QC system
7.6 Quality Management Reports
7.7 Management Reviews
7.8 Monthly Progress Report
08 Progress Control 24 25
8.1 Construction Work Program
8.2 Progress Control
09 Design Quality plan 26 28

9.1 Design Control
9.2 Control of Design changes
9.3 As Built Drawings
10 Quality Control and Assurance in Construction 29 83

10.1 Quality Control of Pavement Works
10.1.1 Methodology
10.1.3 Tolerances of Pavement Work
10.1.4 Inspection Test Plan
10.1.5 Checklist for Inspections
10.2 Measuring and Testing Techniques
10.3Handling and storage of Material
10.4 Identification of Non-conforming Product.
10.4.1 Site Notice / Non Conformance Report (NCR)
10.4.2 Correction, Corrective Action and Preventive
Action.
11 Documents Records and Control 84 85
12 Internal Quality Audit 86 87
13 Training in Quality Assurance 87 87
14 List of Tables 88 94
13.1 List of Materials Tested on site
13.2 List of Materials to be obtained
ManufacturersCertificate
13.3 List of Test and Procedures to be conducted at
Site.
Appendices 5 of 94
A1 Test Report Format
A2 Inspection Test Plan
A3 Inspection Checklists
Department name: Project operation
1.0 Introduction:
The Globalisation and developing Technology in the Construction Industry is

leading to High competition in the Current market. The best response to a
competitive challenge in the Construction Industry is to become more
competitive. The best means of achieving this is by improving the product quality
and meeting the project schedule through a well designed Quality Management
system. The Quality Management system shall focus on providing improved
control on processes and practices, thus enhancing customer satisfaction
through its effective implementation
2.0 Project Scope:
Contract Number : GC10109300

QP Project Number : 3391
Project Start : 27th February 2012.
Mile Stone 1 (Construction Completed) : 26th August 2013.
Mile 2 (Testing, commissioning : 26th February 2014.
& Handover Project Finish)
Construction of the new security gate House and Proposed facility as

Mentioned below, including procurement, installation, pre-commissioning,
Commissioning and testing.
Scope:
Single storied Gatehouse to replace the existing Gatehouse.
A two-storied Security Building with offices for security staff and full height
turnstiles for control of pedestrian traffic.
Shaded parking for security staff cars.
Safe set-down/pick-up bay for two (2) buses.
Demolition and modification of asphalt paved roads, with necessary
Markings and sign boards, including construction of new round about at, new
refinery administration complex access road intersection.
Extension of existing pipeline / utility culverts.
Entrance/exit road barriers and pop-up blockers for vehicular traffic Control.
Bollards for protection of buildings.
Demolition and modification of existing boundary wall.
Heavy duty pre-cast block paving for new security staff car-park and the
Access to this car-park.
Hard landscaping around the buildings, new traffic islands, new round
about, sidewalks and modifications to existing paved areas.
Soft landscaping, to suit the road modifications, including relocation of
Existing trees.
Paved pedestrian walkway, with protection railing, from the bus bay
Extended beyond the new roundabout within the Refinery fence.
All services works, including tie-ins, pertaining to the above buildings and
Site development, including plumbing, drainage, fire-detection system, fire
Management system and other specialist systems, equipments etc.
Security and Access Control system interfaced with Corporate Security

Systems.
3.0 Project Quality Statement

To strive for Quality Excellence, in order to achieve Customer
Satisfaction by Providing goods and services to the standards set by the
customer and to contribute to increasing the Companys competitiveness.
4.0 Revision Status / Amendments and Distribution

The issue number, revision number and revision date are
stated on each page of the Project Quality Manual. Should amendment of the
Project Quality Manual be necessary during the life of the project, only the
revised sub-section shall be reissued and its revision number and date changed
accordingly? Amendments shall be approved by the Head Project Operations
at Head Office. The Revision Status Sheet detailing the amendment, date and
approval shall be issued with each amendment by the Project Manager. Each
new revision shall be distributed as per the original with a request that the revised
sub-sections be destroyed. After ten (10) revisions a new issue shall be
introduced superseding all previous revisions. Registered copies of the Project
Quality Manual shall be distributed to the following:
5.0 Definitions & Terminology
Calibration
All the operations for the purpose of determining the values of the errors of
measuring instruments, material measures, and measurement standards.
Controlled Document
An original numbered copy of a document for which amendments will be
Automatically advised.
Corrective Action
An activity the intention of which is to return a non-conforming item or action to a
Stat or conformity. It also covers action taken to prevent further recurrences of
Non-conformity.
Disposition
An action to be taken concerning material, components or products about which a
Decision has been made.
Document
Any written or printed manual, procedure or form that is part of the quality system.
The term includes documents and data that can be read by people or machines.
Inspection
The careful examination, measurement and testing of the characteristics of
Products and services to ensure they meet regulatory and contractual
requirements.
Inspection and test point

A location or stage in the manufacturing, production or construction cycle where

inspection and testing are performed by personnel whose responsibility is to
determine the acceptability of products or services and to record inspection and test
data.
Non-conformance / Nonconformity
A deficiency in characteristic, documentation, or procedure which renders the quality
of a product or service unacceptable or indeterminate or not according to specified
requirements.
Procedure
A document that specifies, as applicable, the purpose and scope of an activity; what shall
be done and by whom; when, where and how it shall be done; what materials, equipment,
and documentations shall be used; and how it is all controlled.
Product
Material, part, item, component, assembly, sub-assembly structure, plant equipment,
or finished project identified in or described in any standard or specification and
production or obtained as a result of some manufacturing or construction operation
or process.
Product Quality Audit

Inspection of the product at a lesser frequency than the inspection carried out for
normal quality control purposes as an aid to assessing the effectiveness of quality
control.
Quality Assurance
All those planned and systematic actions necessary to provide confidence that
products or services will satisfy given requirements.
Quality Audit
A systematic and independent examination to determine whether quality activities

and related results comply with planned arrangements and whether these
arrangements are implemented effectively and are suitable to achieve objective.
Quality System Audit
The independent examination of an organizations quality assurance system carried

out by an auditing team from within or outside the organization.
Quality Control
Those actions which provide a means to measure and regulate the characteristics of
a product or service to establish requirements. Operational techniques or activities
(e.g. inspection or test) used to verify technical and quality requirements for services
and or products.
Quality Policy
The overall quality intentions and directions of an organization as regards quality, as
formally expressed by top management
Quality Plan
A document setting out the specific quality practices, resources, activities and
responsibilities relevant to a particular contract or project.
Remedial Action
An action to be taken concerning material, components or products about which a
decision has been made.
Repair
The process of restoring a non conforming characteristic to a condition such that the
item conforms to the original specified requirements, where such a repair or
restoration is acceptable.
Verification
Confirming that an activity or condition conforms to specified requirement

6.0 Quality Policy, Quality System and Quality Strategy
6.1 Quality Policy Concept
The Quality Policy is communicated and made understood at all level of the
organization through awareness program an display of the Quality Policy boards at
all the Project sites/departments. The Quality Policy shall be reviewed annually for
continual improvement and suitability to the purpose of the division. Taking Quality
Policy as guide, the quality objectives are established in related functions and
monitored in the monthly steering committee meetings and periodic Management
Review meetings. Management review includes review of Quality objectives and
specific policy statements with the view to achieve Quality objectives and meeting
the requirements of the policy statement.
6.1.1 Quality Policy:
We aspire to fulfill the expectations of our customer by a dedicated and organized

approach, which is amenable to skill and knowledge enhancement. We shall improve
the competence of our Quality management System continually. Our focus to
accomplish this aim shall be on:
Effective design
Effective Implementation of planning and Methodology
Effective Supplier Management
Proficient Management of Workforce.
Training and development of Human Resource.
6.1.2 Quality System.
The Quality System has been designed to ensure that the

Quality Policy, objectives and the requirements of ISO 9001:2008 are implemented.
The system has been determined in terms of the following main processes.
Estimation, Costing and Tendering

Design and Engineering
Quality planning and Control

Planning, Monitoring and Control
Plant and Machinery provision
Project Operation
Commercial, Contract and Procurement

Personnel and training
Finance
Quality System
6.1.3 Structure of Quality management System documentation
QUALITY POLICY
Quality management manual
Other quality documents (standards, Records, Guidelines Checklist etc...

Quality process and procedure manual Project Quality Plan
6.1.5 Quality Management System Manual:

This quality Management system manual describes the purpose
and scope of the Quality management system. Interaction of functional process and
establishment of documented to fulfil requirements of ISO 9001:2008 standard. The
applicable causes of ISO 9001:2008 standard have been included in the chapters
describing the systems as applicable.
6.1.6 Quality Process and Procedure manual:

The Procedures are established to meet the requirements of ISO
9001:2008 and are included in the quality process and procedure Manual. These
procedures covers control of documents, control of records, internal quality audit,

control of non conforming products and corrective / preventative actions.
6.1.7 Project Quality plan:

A definite quality plan for every project, detailing there in the
activities, Acceptance criteria, Verifying documents, controlling agency
(Organization/Customer) and the type of control and responsibility for implementing
the activity and its control, including resource requirements are developed before
start of the Project.
6.1.8 Other Quality Documents:

Quality records and formats from this level of documents. Other
standards, check list and guidelines are also used for the supports of overall quality
system structure.
6.1.9 Quality Strategy:

Implementation of the quality Management system and its
effectiveness is ascertained by periodical monitoring as well as by structured internal
quality audit and corrective and preventive action to ensure improvement in
effectiveness of the Quality system in operation. A continuous process of feasible
Technology up gradation and value analysis is initially targeted at persisting un
solved non-conformities to be attended to as well as potential problems.
Management review of the quality system is conducted periodically, to check for
continued suitability for effectiveness, towards meeting the requirement of the
organizations Quality Policy and objectives. The integrity of Quality Management
System is ensured when changes are planned and implemented.
6.2 Planning
This Project Quality Manual is the document which details the Quality
System to be planned, established, implemented and maintained as part of the
contract for the road works for the project The Project Quality Plan consists of the
following:
(i) The Project Quality Statement of the company
(ii) Project Specific Details including Organization and System Element Description.
(iii) Inspection and Test Plans (including Construction Process Flowcharts and
Quality Verification Checklists).
(iv) Project specific Procedures as required by the contract specification /

concession agreement
The Project Quality Manual describes the managerial and technical systems which
shall be implemented to achieve conformance to specified requirements. The
systems shall cover on site work under the contract. Where necessary the systems
shall be extended to include offsite activities. The inspection and test plan shall
identify necessary inspections and tests to verify conformance of the work during
performance of the identified project tasks. It shall include acceptance criteria and
details for performance of inspection and test activities, as applicable.
6.3 Control Control shall be achieved by implementing the requirements of the
Project Quality Manual including construction process controls, inspection and test
plan and audit requirements. Continuous monitoring and the investigation of timely
corrective action shall form the basis of control. System Element Descriptions shall
detail the methods by which the quality system is controlled. The agreed Inspection
and Test Plans shall be used for controlling the work and detecting non-
conformance.
6.4 Verification Verification processes shall be established to ensure that the
planning and controls have been effective and the Quality System and constructed
works conform to the specified requirements. The outcome of all verification activities
shall be documented and maintained as quality records. Records of conformance
shall be available for inspection by the Client / Clients Representative upon request
to provide evidence of the outcome of activities undertaken to achieve conformance.
7.0 Quality Management in Construction and Reporting
7.1 Management Responsibilities:
The Head Project Operations has the overall responsibility for construction of the
project, ensuring Customer satisfaction. The Chief Project Manager of Project will be
in charge of this Project and will be reporting to the Head Project Operations.
Project Quality Plan will be implemented by the Chief Project Manager. The Project
QA/QC team will interact with QA /QC team of Client / Clients Representative for
review of material tests, mix designs and QA/QC procedures as per the Project
Quality Plan and reports functionally to Head QA/QC H.O. The Head QA/QC H.O
will report to the top management and act independently to implements QA policy of
the Organisation. He has the responsibility for formulating, implementing, reviewing,
monitoring, verifying and assessing the effectiveness of Quality Assurance program.

He has also been delegated the authority to take corrective measures in case of any
significant quality related problems are noticed, with the intimation to the Chief
Project Manager.
7.4 Responsibilities of staff at Project Execution Team:
7.4.1 Project Manager the Project Manager for the project has the following
responsibilities
Overall Management of this Project. He shall have the authority and
responsibility for time, cost, and safety and quality aspects of the Project.
Determining the policy with respect to the management of quality on the

project.
Issuing the Project Quality Plan including System Element Descriptions and
Inspection and Test Plans.
Approving the disposition of Non-conformance Reports issued by the

authorized representative nominated by him.
Communication and interface between CLIENT, Contractor, Subcontractors

and the Project team.
7.4.2 Team Lead - Execution

The Construction Manager for the project has the following responsibilities
Responsibilities for the planning, implementation, control and maintenance of
the Project Quality Plan.
Issue all relevant documentation and amendments to the Project team.
Guide and instruct others in the essential aspects of quality management.
Verification of inspection and test activities.
Liaise with the contractor in regard of Final Inspection and Acceptance of the
work.
Apply acceptance criteria and classify work as conforming or Non-
conforming. Issue Non-conformance Reports where necessary.
Recommend remedial action and re inspect to close out.
Recommend corrective action in case of recurring non-conformance.
Communication and interface between CLIENT, Contractor, Subcontractors
and the Project team

7.4.3 QA & QC Manager
The QA & QC Manager for the project has the following responsibilities.
Responsibilities for the planning, implementation, control and maintenance of
the Project Quality Plan.
Guide and instruct others in the essential aspects of quality management.
Liaise that the quality of manufacture and construction satisfies the standards.
Ensure that suitable measuring and testing equipment is available and
calibration of same is monitored regularly.
Verification of inspection and test activities.
Recommend remedial action and re inspect to close out.
Recommend corrective action in case of recurring non-conformance.
Responsible for preparing Monthly Quality Management Report
Interaction with CLIENTs representative, approval of all materials as per CA
in day to day basis.
7.4.4 Execution Engineer
The Execution Engineer has the following responsibilities.

o Assist Project Manager in all aspect of Project Management.
o Responsible for overall execution of all aspect of Pavement as per working
drawing and inspection of works on site as per Contract agreement, Specifications
and Project Quality Plan.
o Monitor and Guide the Project Team in aspect of Project Progress, Quality and
Safety.
o Recommend corrective action in case of recurring non-conformance.
o Responsible for Participating in preparation of Monthly Progress Report.
o Interaction with CLIENT all aspect of works.
7.4.5 Safety Manger

The Safety Manger of the project has the following responsibilities.
o Assist Project Manager in all aspect of Safety and Environment Management
compliance as per Contract Agreement.
o Responsible for overall implementation of Safety and Environmental Compliance
plan.
o Monitor, Inspect and Guide the project team in aspect of Safety, Environmental
Compliance w.r.t Contract agreement.
o Carry out regular inspection in line with the requirement of contract agreement and
recommend corrective action in case of recurring non-conformance.
o Responsible for participating in preparation of Monthly Progress Report.
o Interaction with CLIENT regarding all aspect of Safety and Environmental
Compliance plan.
7.4.6 Planning Engineer & Quantity Surveyor
o Responsibilities for monitoring on day to basis the planned target and

achievement. If any shortfall report to Project Manager, finding reason and make
internal revised macro program to make up the shortfall.
o Responsible for preparation of Monthly Progress Report.
o Responsibilities for maintaining all documentation related to progress, verification
of quantity in B.O.Q.
o Generating all compliance report required to be submitted.
7.4.7 Lab In charge
o Assist QA & QC Manager with the setting up of Field laboratories.

o He is the overall in- charge of testing, review and approval all material to be used
for permanent works.
o Review and acceptance of quarry sites for aggregates , quarry spall , sand ,
borrow material Mix design for Concrete and pavement layers , and other bought out
items to be used for the
project.
o Supervise all the tests to be done in different stages of construction, besides

ensuring that specified tests are done as per specifications, stipulated codes and
Contract agreement.
o Maintain record of all materials at site and review the procurement schedule and
assist the Project manager and Senior Material Engineer (SQME) in issuance
instruction for correcting the same.
o Organizing independent tests other than the regular tests done by laboratory
personnel.
o Verify manufacture test certificate and ensure quality control testing of all materials
and completed works are as per the technical specifications.
7.4.8 Surveyor
o Report day to day basis to Construction Manager in all aspects of Survey work.
o Responsible for organizing for detailed survey for the Pavement, checking
alignment, Horizontal and vertical profile, Cross section w.r.t to the designed profile.
Any difference shall be reported to Construction.
o Preparation of Cross-section for execution.
o Checking Lines and levels for the execution of works in accordance with drawing
and Contract Agreement.
7.5 Functions of QA / QC System: i) For each major activity of work, method
statement will be prepared indicating the quality checks for incorporated materials
and stage of construction. Detailed description shall be followed in later part of this
section 10. ii) Ensure that equipment and testing instruments are calibrated properly
and adjusted to maintain their accuracy within acceptable limits. iii) Provide day to
day routine checks on materials and finished products. iv) Identify problems and
initiate action, which results in solution. v) Verify implementation of solutions /
corrections.
vi) Report regularly on effectiveness of the system. vii) Tests to be performed jointly
with Contractor and CLIENT at site before start of any activity and after review /
approval of the same activity have to start. viii) All the test reports have to be certified
by the Contractor and CLIENTs Representative. CLIENT has to nominate his
representatives for joint testing during site working hours. In case of non availability
of CLIENTs Representative, tests will be carried out by Contractors QC Engineer
under information in the interest of work. ix) All records of qualifying and routine tests
/ checks will be jointly maintained at the QA/QC MANAGERs office. x) Monthly
Project QA report will be prepared by project QA/QC MANAGER, summarizing the
activities of QA department which is to be submitted to Management. xi) Head of QA
from H.Q shall deploy his representative to carry out internal quality audit to ensure
compliance of quality measures covered hereunder and to make necessary
improvement, if required in quality system. xii) Project Manager / QA & QC In-charge
through his representative at site will point out the non-conformity of standards if any,
to the contractors authorized representative in writing and a copy of the same to be
sent to the General Manager for getting the work done as per quality standard
required as specified in Contract Agreement, quality specifications or drawings.

CLIENT, Contractor, Sub contractors, Material supplier and Manufacturer, each form
a link of the quality chain. The strength of this chain is dependent on each and every
link. The QA/QC MANAGER is to keep a continuous watch on this chain and spot
the weak link before it snapped.
7.6 Quality Management Reports: The QA/QC in-charge at site shall prepare a
Monthly Quality Management Report for review by the Project Manager /
Construction Manager. The Quality Report shall be subdivided into the following
headings: Summary of Inspection and Test Activities. (Field & Laboratory) Registers
of Non-conformance & Corrective Action. Status of Approvals of all Materials.
Outstanding approvals by the CLIENTs Representative Items of specific concern.
General Notes The Quality Management Report shall be submitted to the Project
Manager within one week of the close of the monthly reporting period and in turn Site
shall forward this to Head Office (QA) within 5th of every month for record and
distribution to the respective section in charge for record and action required if any.
7.7 Management Reviews: The operation and effectiveness of the Project Quality
Plan shall be regularly reviewed by Management Review meetings held once in Two
months for the duration of the project. The monthly Quality Management Report
together with Audit Reports shall form the basis of the review. The Management
Review meetings will be attended by the CEO, Head Project Operations,
Management Representative, and Project Management team. Minutes of the
management review meeting will be taken by the MR. He shall be responsible to
prepare and distribute minutes to the members of the review Committee for their
information and action.
7.8 Monthly Progress Reports: The Monthly progress report shall be prepared at
site and submitted to the CLIENT as per requirement of Contractor agreement. The
detailed format for the report, contained all the activities of the month, major
achievements, miles stone achieved, progress, quality control reports, problems,
issues etc.
8.0 Progress Control This section of the Manual outlines requirements and
procedures for construction scheduling and control of work progress. 8.1
Construction Work Program The Contractor is required to submit a detailed work
program for execution of the works as per the QMS Process S00/PO/P/03 Project
Planning & Budgeting process site. This program must show the following, as a
minimum:
Itemized work activities to be executed, based on the Contracts Bill of Quantities,
indicating start and finish dates and scheduled achievement (progress) each month;
Sequencing of work and activity interdependence;
Calendar day estimates for submittal approvals; and
Calendar dates for achievement of various milestones, and for completion of works
by section and of the project as a whole, within the time periods provided for in the
Contract.
The Contractors program should show the critical path activities, and the float
available for activities outside the critical path. It should preferably be prepared
based on a commercially available project scheduling software package, such as
Microsoft Project / Primavera. The Contractor should also furnish a breakdown of his
anticipated monthly earnings for payments in accordance with the terms and
conditions set forth in the Contract. Based on work program, Contractor shall review
and submit it to the CLIENT as stipulated in the Contractor agreement for his review
and approval. Once approved, the program cannot be modified except with the prior
approval of the CLIENTs Representative. The CLIENT approval of the program
does not relieve the Contractor of his obligation to complete the works or sections of
work within the time periods stipulated in the Contract Agreement.
8.2 Progress control
The Contractor is required to undertake its activities in accordance with the approved
work program. Each month the contractor shall indicate the actual work completed
as compared to work scheduled as per the QMS Process S00/PO/P/04 Project
Monitoring Process site. In the event portions of the work are in danger of being
delayed, or actually are delayed, the contractor is to determine a plan for remedial
action. Various circumstances may justify the changing of contract requirements for
completion of the project on a specific date. Among these circumstances are items
not within the control of the Contractor, such as: changes to contract requirements
(modification of Contract); suspensions of work; delays in providing access; force
majure, etc. Generally, such occurrences will justify a delay in completion if they
affect activities on the critical path of the program. However, each instance must be
carefully evaluated and fully documented before a decision can be made. The
following are guidelines for controlling work progress:
There should always be a baseline program. If changes to the baseline program are
required, an updated baseline program (baseline program no. 2, etc.) should be
created.
Unauthorized changes to completion milestones should not be allowed, unless
authorized by a contract modification.
Contractor shall monitor the progress of works and should update their completion
percentages and report to CLIENT through Monthly Progress Report.
When actual progress falls behind scheduled progress or when it appears that a
milestone will not be completed on time, the Contractor must identify the reasons for
delay and in conjunction with CLIENT the Contractor make recommendations for
remedial actions.
9.0 Design Quality Plan The Contractor shall engage a Design Consultant for the
preparation of detailed designs and drawings as per the QMS Process S00/DE/P/01
Design Consultants Registration and Pre qualification process &
S00/DE/P/02 Design Consultants Final Selection Process. The Contractors
Design Consultant shall submit the designs and drawings to the Contractor and the
Contractors Design Review Team shall review and check these designs and
drawings before they are forwarded to CLIENT for their comments and approval.
9.1 Design Control This section of the PQP outlines the requirements for the control
and management of the designs which are prepared by the Design Consultant as
per QMS process S00/DE/P03 Design Management Process. All designs and
drawings, including design calculations, shall be prepared by the Contractors
Design Consultant, based on the Employers Requirements in the Contract and in
accordance with applicable design standards and criteria, codes, and methodology.
The drawings shall basically show details of the Works and, where applicable, their
sequence of construction. Prior to carrying out any designs, the Contractor and the
Design Consultant shall arrange to procure all the survey and site data such as
pavement evaluation. Data provided by the Employer as part of the Tender
Documents shall be verified through confirmatory survey and investigations. The
Design Consultant shall also prepare a Design Brief listing out all the design criteria
to be adopted for the designs of the Works. This shall be checked by the
Contractors Design review team and if in order, this shall be submitted to the
Employer for their comments and concurrence. This Design Brief shall then form the
basis of all designs and drawings of the Works. Drawings shall generally be
prepared by computer aided design methods.
The flow of design documents shall generally be as follows:-
a) The Design Consultant shall prepare all designs and documents and have them
internally checked as per their own design quality control plan. All designs and
drawings shall be signed and dated by the Design Consultants draftsman, designer
and the design checker.
b) These documents shall then be submitted to the Contractor. The Contractors
Design Review team shall check the drawings and calculations for completeness,
correctness, legibility and conformance to the contractual requirements.
c) These designs and drawings shall then be submitted to the Employer in such
number and format as stated in the Contract for their review, comment and approval.
d) The Employer or the Employers Representative shall review and comment on the
Contractors designs and drawings. Regular meetings shall be arranged between the
Employers Representative, Contractor and Design Consultant in order to expedite
the process of review and concurrence of the designs and drawings.
e) The Employers Representative shall signify no comment or comments made
or resubmit and return one copy of the designs and drawings to the Contractor.
f) The notes no comment or comments made will enable the Contractor to
proceed with the construction of the relevant works. The Contractor shall issue these
drawings to the sub-contractor for construction.
g) Where the designs and drawings are marked resubmit, then such documents
shall be amended, modified or prepared again and resubmitted to the Employer. The
process as mentioned above shall be repeated until the Employers Representative
signifies no comment or comments made on these documents.
h) The Contractor shall maintain a detailed register of all designs and drawings and
the status of their submissions and review by the Employer.
9.2 Control of Design Changes This section of the PQP outlines the requirements
for the control and management of the designs Changes as per QMS process
S00/DE/P03 Design Change Management Process.
The Contractor may initiate design changes due to site conditions being different
from that envisaged during preparation of the initial designs, or for other reasons.
The Employers Representative may also order changes as provided for under the
Contract. The Contractor shall provide Design Consultant with all the necessary
instructions and site information, and the Design Consultant shall prepare the design
changes, together with the design change report, where applicable. The process for
submission, checking and concurrence the design changes by the Design
Consultant, the Contractors Design Review team and the Employers
Representative shall be the same as set out for designs and drawings under item 9.1
above. The Contractor shall keep the sub-contractors informed of any imminent
design changes and shall issue the revised drawings to the sub-contractor for
construction for construction soon after the drawings are concurred by the
Employers Representative. The Contractor shall update the design and drawing
register for the design changes made.
9.3 As-Built Drawings The Contractor is responsible for the preparation and
submission of as-built drawings once the Works are constructed and completed.
During the course of the construction works, the Contractor shall maintain a
complete set of the latest construction drawings marked up with the as-built details.
The as-built details shall be updated on a regular basis until the whole of the Works
are completed. Where revised drawings have been issued to incorporate design
changes, the as-built details shall be transferred and marked up on the revised
drawings. Upon completion of the Works, the Contractor shall prepare as-built
drawings incorporating all the as-built data collected and submit the as-built drawings
to the Employers Representative in the format and number as specified in the
Contract and as required by the Employers Representative. The Employers
Representative shall review these as-built drawings and after reviewing, shall
endorse them as reflecting the as-built details of the Works.
10.0 Quality Control and Assurance in Construction 10.1 Quality Control of
Pavement Works: QA/QC Performing required Mix designing Reject the Source Mix
design approved by Client Getting approval For Mix Design from Client Flow Chart
for Quality Control At Site Responsibility Identification of Source for material RFI for
Sampling and testing Joint Sampling and testing with Client Source approved by
Client N Y N Registering and Use for Construction Y RFI for Work to be excuted
Joint Inspection with Client Conducting necessary field and laboratory testing Work
Approved by Client Start next stage of work Y Non Conformance by Client N Repair /
Removal / Demolish as per instruction by Client Rework
10.0 Quality Control and Assurance in Construction 10.1 Quality Control of
Pavement Works: QA/QC Performing required Mix designing Reject the Source Mix
design approved by Client Getting approval For Mix Design from Client Flow Chart
for Quality Control At Site Responsibility Identification of Source for material RFI for
Sampling and testing Joint Sampling and testing with Client Source approved by
Client N Y N Registering and Use for Construction Y RFI for Work to be excuted
Joint Inspection with Client Conducting necessary field and laboratory testing Work
Approved by Client Start next stage of work Y Non Conformance by Client N Repair /
Removal / Demolish as per instruction by Client Rework
CONSTRUCTION QUALITY CONTROL:
General: Quality control of materials forms an integral part of the overall construction
and supervision function. Taken properly into account, it provides the link between
the design and the finished works. Testing of construction materials is carried out for
a variety of reasons and purposes including:
Screening Tests (e.g. choosing a borrow source, an aggregate supplier, a
manufacturer / supplier of cement etc.)
Control Tests (e.g. sampling and testing of cement material delivered to site to
confirm adherence to project specifications and to confirm manufacturers Test
Certificate)
Audit Tests to verify independently the reported properties of materials
Trial Mixes (selection of appropriate concrete mix designs, design of bituminous
mixtures etc.)
Acceptance Tests (e.g. testing of cubes cast of produced concrete to confirm that
required strength is achieved and is consistent)
Special testing as may be deemed necessary and prudent
Suppliers of manufactured materials such as cement, steel, bitumen, bearing pads,

Expansion Joints, Runway Furniture etc. shall be screened based on submissions,
review of sample Manufacturers Test Certificates and experience on previous
projects of the manufacturer. Independent testing by third party in the presence of

Contractors and CLIENT Representative may be carried out if required.
Control and approval of construction materials shall be based on the following:
Test reports for materials tested , such as cement, sand, water, soil, aggregates
and bitumen; and
Manufacturers certificates for materials such as steel, cement, admixtures etc.
The details of input materials should be recorded in a Materials Register (See

Format in Appendix A4).
All test results shall be entered into a test logbook / register maintained at site
laboratory, with an indication of conformance/non-conformance. A format for test
report log is given in Form in Appendix A4. This section hereinafter provides an
overview of control requirements for materials, including site testing and
manufacturers certification. All materials to be incorporated and all works performed
shall be strictly in conformity with the Contract agreement and specification
requirements. Laboratory at locations shall be set up by the Contractor. The
laboratory will be equipped with sufficient number of modern and efficient equipment
suitable to carry out the tests prescribed for different materials and work according to
the Contract agreement and specifications. The equipments shall be procured to
conduct the specified test as per MORT&H and facilities to be provided.
The laboratory will be manned by a qualified Material Engineer assisted by
experienced Engineers, Technicians, Laboratory helpers and the set-up will be got
approved by the CLIENT.
Test shall be carried out quality controls on the materials and work to the frequency
described in subsequent paragraphs. In the absence of clear indications about
method and or frequency of tests for any item, the direction of the CLIENT shall be
followed.
For satisfying himself about the quality of the materials and work, quality control tests
will also be conducted by the Contractor / CLIENT, generally to the frequency set
forth herein under. Additional tests may also be conducted where in the opinion of
the CLIENT need for
such tests exist.
For the work of pavement, construction of subsequent layer of some or other

material over the finished layer will be done after obtaining approval from the
CLIENT. Similar approval from the CLIENT will be obtained in respect of all other
items of works to proceeding with the next stage of construction.
Defective / Inferior quality of work shall be modified in the procedure of work, if found
necessary, as directed by the CLIENT during inspection.
The Contract rate quoted for various items of works by the contractor in the Bill of
Quantities or the lump sum amount tendered will be deemed to be inclusive of all
costs of the quality control test and operations necessary for ensuring quality of the
material and work so as to be in conformity with specification requirement.
All the tests to be conducted at laboratory and at site shall be documented as per the
format specified in the later part of the section. Usually the documentation shall be
maintained in such a fashion that it shall be very easy traceable with a specific RFI
No. mentioned with date in layer chart for Pavement and in turn this shall be filed
with bituminous and Non-bituminous in a separate file / volume as a lot with several
sub lot. For all routine test for Pavements and other works, Borrow areas result,
Bought out items shall be maintained in a separate lot irrespective of section.
10.1.1 Methodology:
SURVEY WORKS
1. Topographical Surveying
The Surveying actively is undertaken for the determination of control points and to
afford sufficient data for the designing of engineering work such as site preparation
and pavements. In the beginning of commencing works on any project, the following
data shall be collected from Customer (Engineer / employer) or prepared by the
Contractor.
1.1.1 Vertical Control Points (VCP) The records of all GPS Points carrying details
shall be obtained from Customer (Engineer / employer). The data shall also include
the Reduced Levels (RLs) of all TBMs fixed with location sketch and adjustment
details from GPS to GPS.
1.1.2. Horizontal Control Points (HCP) The records of all GPS Points (X, Y)
position and intermediate traverse points with location sketches shall be received
from Customer (Engineer / employer). The data shall also include traverse carrying
data and adjustment details from GPS to GPS Point.
1.1.1.3 Proposed Centerline Coordinates The co-ordinates (X, Y) for proposed
centerline of the pavement. at a regular interval as specified by Customer (Engineer /
employer) shall be obtained.
1.2. Survey works Survey actually in any project involves three stages of surveying
necessary to be carried out at project sites. The survey work shall include
a) Preliminary Survey works:

Before starting the construction activity, Temporary Bench Marks (TBM), shall be
established on the ground at specified interval. The control pillars shall be
constructed before start of conformation survey for VCPs & HCPs. The pillars shall
be constructed in staggered position within the project premises. The visibility
between proceeding pillar to succeeding pillar shall be maintained. The control pillars
are fixed at regular intervals of 250 or 200 meters.
The TBMs shall be used as reference points for executing the works in the particular
reach. The TBMs shall contain Reduced Levels of the ground and changing of that
location. These shall be
Checked periodically once in 3 months to ascertain the sanctity of levels. The levels
shall be entered as per Rise & Fall for TBM Verification. The data shall be used for
preparing site leveling & earthwork excavation plan, cross-section of the Pavement
and working drawings. The centerline is also fixed for reference and execution.
1.3 Survey work while execution
Based on the reference of TBM along with reduced levels and centerline, each
activity of the work during execution shall be carried out.
1.4 Survey work on completion of job After completion of work, Reduced Levels
shall be taken up on the works, so as to ascertain the true levels as mentioned in the
drawing are transferred to site. In case of any deviation, such changes shall be
recorded and as built up drawing shall be prepared.
1.5 Confirmation of Survey works Immediately after receiving the survey data
from the Customer (Engineer / employer), the Contractor shall confirm the survey
data of the entire project. The confirmation process shall include the following
aspects
1.5.1 Confirmation of Vertical Control Points The confirmation of Vertical Control
Points (VCP) shall be undertaken by surveying from GPS to GPS points. The Rise
and Fall method shall be adopted for TBM Confirmation Survey. The control pillars
established shall be connected by this survey work. The TBM level after the survey
work is recorded.
1.5.2 Confirmation of Horizontal Control Points The confirmation of Horizontal
Control Points (HCP) shall be undertaken by surveying from a pair of GPS points to
another pair of GPS Points. These values shall be checked with the values given by
the Customer (Engineer / employer). The traverse points established shall be
identified with nail punched on top of Pavement to get the exact point and shall be
encircled with paint of golden yellow color.
1.6 Transferring Survey Data to Control Pillars
1.6.1 HCPs to Pillars Once survey data of HCP is confirmed and control pillars are
constructed, the coordinates (X, Y) shall be transferred from nails to control pillars by
the Total Station. The transferring of levels and coordinates from nails to pillars shall
be prepared.
1.6.2 VCPs to Pillars Once levels of TBM are confirmed and control pillars are
constructed, the levels (Z Co-ordinates are transferred from permanent benchmark
to pillar. The transferring of levels from permanent benchmark to Pillars shall be
prepared.
1.7 Detailed Survey work for runways and Taxiways
a) Setting out of proposed pavement centerline and construction of Reference Pillars

shall be made after completion of confirmation survey works. Once the centerline is
established, reference pillars shall be constructed on both sides of Runway. The
centerline reference sheet containing data on reference pillars is given Centerline
Reference Sheet.
b) OGLs are recorded before disturbing the existing ground level. Any construction
activity i.e. clearing and grubbing etc. shall start only after taking OGL. In case of
dense vegetation, removal of vegetation could start without disturbing ground level.
OGLs are recorded in Field Book
1.8 Detailed Survey works for Structure

Before setting out of centerline of new structures i.e. culverts and retaining head
walls etc. site should be clean of all the logs, stamps and other deleterious matter,
which may interrupt grid level. The contractor shall remove all water from
waterlogged areas near Structures by suitable dewatering pumps. For controlling
vertical and horizontal points for structural works, reference pillars are required to be
constructed depending on type of structure. Separate pillars shall be constructed for
VCP and HCP in structure location.
1.9 Instrument The work shall be carried out with Auto level instrument and Total
Station. The recent calibration report of the instruments shall be submitted and
approval shall be sought from the Customer (Engineer / employer) prior to the start
of levelling work in the field. The MS Plate shall be used for every change point to
support levelling staff, depending on the condition of the ground.
CLEARING, GRUBBING AND DISMANTLING STRUCTURES (Acceptance
Criteria: Ref. Section 200 of MORT&H)
1. General This work shall consists of cutting, removing and disposing of all
materials such as trees, bushes, shrubs, roots, grass, weeds, top organic soil not
exceeding 150mm. Dismantling of structures acquired within ROW in brick work,
stone masonry, plain/ reinforced concrete, timber structures, removing tiles, GCI
sheets, etc., and sorting out dismantled materials, disposal of unserviceable
materials and utilizing the serviceable materials at free of cost.
2. Procedure for clearing and grubbing:
Original ground levels shall be recorded jointly before commencing C&G activities.
Before starting the Clearing and grubbing activity, information to the Client / Clients
Representative given.
Top-soil and deleterious material will be dozed and removed up-to 150mm
thickness .All the dozed top soil will be removed from toe line and stacked /displayed
away from the area of work.
All the trees, shrubs and roots will be removed from the stretch with the help of
manpower / machineries.
Backfilling of the pits will be carried out if required with sand, saturated fully with
water.
After completing the clearing and grubbing check-list will be complied.
3. Procedure for dismantling structures:

Measurements shall be recorded jointly before dismantling of structure.
The structure shall be carefully dismantled and the resulting materials so removed
shall not cause any damage to the serviceable materials and the structures nearby.
The connecting edges shall be cut, chipped and trimmed to the required lines and
grades without weakening or damaging any part of the structure. Due care shall be
taken to ensure that the reinforcement bars which are to be left in place so as to
project into the new work as dowels or ties are not injured during removal of concrete
while extending the existing culverts/ bridges.
Equipment / Machinery Requirement:
1. Dozer
2. Excavator
3. Tippers
In dismantling pavements, MS pipes, guard rails, kerbs, gutter, and fencing, where
portions of existing construction are to be left in the finished work, the same shall be
removed to an existing joint or cut/chipped true to the lines with face perpendicular to
the existing structure.

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Al Fowriya Trading &

Project Quality Plan Contracting

Al Fowriya Trading & Contracting W.L.L.

Project Quality Plan

Project: CONSTRUCTION OF NEW SECURITY GATE HOUSE AND

Client: M/s. Qatar Petroleum

Prepared By Checked By Approved By

QA/QC Engr FTC Project Manager FTC QP EDM

09 Design Quality plan 26 28

10 Quality Control and Assurance in Construction 29 83

The Globalisation and developing Technology in the Construction Industry is

2.0 Project Scope:

Contract Number : GC10109300

Construction of the new security gate House and Proposed facility as

Security and Access Control system interfaced with Corporate Security

3.0 Project Quality Statement

4.0 Revision Status / Amendments and Distribution

5.0 Definitions & Terminology

Inspection and test point

A location or stage in the manufacturing, production or construction cycle where

Product Quality Audit

A systematic and independent examination to determine whether quality activities

The independent examination of an organizations quality assurance system carried

Confirming that an activity or condition conforms to specified requirement

6.0 Quality Policy, Quality System and Quality Strategy

6.1 Quality Policy Concept

6.1.1 Quality Policy:

We aspire to fulfill the expectations of our customer by a dedicated and organized

6.1.2 Quality System.

The Quality System has been designed to ensure that the

Estimation, Costing and Tendering

Quality planning and Control

Commercial, Contract and Procurement

6.1.3 Structure of Quality management System documentation

Quality management manual

Other quality documents (standards, Records, Guidelines Checklist etc...

6.1.5 Quality Management System Manual:

6.1.6 Quality Process and Procedure manual:

procedures covers control of documents, control of records, internal quality audit,

6.1.7 Project Quality plan:

6.1.8 Other Quality Documents:

6.1.9 Quality Strategy:

(iv) Project specific Procedures as required by the contract specification /

monitoring, verifying and assessing the effectiveness of Quality Assurance program.

Determining the policy with respect to the management of quality on the

Approving the disposition of Non-conformance Reports issued by the

Communication and interface between CLIENT, Contractor, Subcontractors

7.4.2 Team Lead - Execution

The Execution Engineer has the following responsibilities.

7.4.5 Safety Manger

o Responsibilities for monitoring on day to basis the planned target and

7.4.7 Lab In charge

o Assist QA & QC Manager with the setting up of Field laboratories.

o Supervise all the tests to be done in different stages of construction, besides

required as specified in Contract Agreement, quality specifications or drawings.

Suppliers of manufactured materials such as cement, steel, bitumen, bearing pads,

projects of the manufacturer. Independent testing by third party in the presence of

The details of input materials should be recorded in a Materials Register (See

For the work of pavement, construction of subsequent layer of some or other

a) Preliminary Survey works:

a) Setting out of proposed pavement centerline and construction of Reference Pillars

1.8 Detailed Survey works for Structure

After completing the clearing and grubbing check-list will be complied.