SALIENT ASPECTS OF
QUALITY ASSURANCE & QUALITY
CONTROL CONSULTANCY FOR NSP
MODERNISATION & REHABILITATION
WORKS UNDER APWSIP
G.PRABHAKAR FIE
PREAMBLE
In order to attain the best and sustainable
quality of construction, Govt. and World
Bank desired to appoint. THIRD PARTY
QUALITY ASSURANCE / CONTROL
CONSULTANTS to work in coordination
with the Project Engineers.
PRINCIPLES OF QUALITY
• Quality planning prevents pathetic
performance. Quality lives on long after the
price is forgotten.
What is Quality ?
• Fit for purpose, suitable for the intended
purpose.
• Many experts defined Quality in many ways.
JURAN (father of quality or a quality guru)
defined that
• a greater number of features that meet
customer needs and has
• fewer deficiencies.
PHILIP CROSBY defined that
Quality is that which meets every possible technical
specifications and it consists of
1. Design
2. Make it , test it
3. Use it
4. Test it in service
EDWARDS DEMING defined as
Conformance to requirement
QUALITY PLANNING
• to establish quality goals.
• to identify the needs of work.
• to develop process which enables to
produce the desired specifications.
• to establish process controls.
QUALITY IMPROVEMENT
• to establish infrastructure.
• to establish project team.
• to provide the team with resources
training.
QUALITY ASSURANCE
• Assurance :
The act of giving confidence,
the state of being certain or the
act of making certain
• Quality Assurance: The planned and systematic
activities implemented in a
quality system so that quality
requirements for a product
will be fulfilled.
QUALITY ASSURED BY
• Quality of
• Input Materials
Quality of end
product
Adherence to
specifications
QUALITY CONTROL
• CONTROL : An evaluation to indicate needed
corrective responses, the act of guiding a
process in which variability is attributable to
a constant system of chance causes.
• QUALITY CONTROL: The observation
techniques and activities used to fulfill
requirement for quality.
INTRODUCTION
Rehabilitation & Modernizations works relating to
- Main Canals ..2
(Right 203 Km + Left 297 Km)
- Branch Canals 16 (Right (9) 269 Km + left (7)
198Km)
- Major Distributories : 158
and entire Network of distribution.
- Dam Safety Works
- Lift Irrigation Schemes 165
These works involve types of construction,
construction Materials and procedures /
Techniques.
CONSULTANTS TO PROVIDES THE
SERVICES
i) to monitor the quantity and progress.
ii) to ensure strict enforcement of specifications by
developing check lists, OK Cards
iii) to develop formats for testing different items of
input materials and finished items of work.
iv) to conduct training to the key personnel of all
project related agencies.
REPONSIBILITIES
OF
PROJECT ENGINEERS
CONSULTANTS.
CONTRACTOR,
AND QA/QC
A. CONTRACTOR (Party- I)
.
.
.
Worker programme – Quality Management plan
shall be handed over to the site Engineer &
Consultants.
Shall have adequate Lab. Arrangement for
conducting 100% quality tests.
Shall maintain OK cards – before commencement
during execution and after completion – carry out
deficiencies pointed out.
• Shall maintain the Test Reports and make
available for inspection and verification.
• Shall carry out corrective actions on the
observation of Project Engineers and
Consultants
• Shall preserve all the records as OK Cards, Site
order Register, Test Reports till specific
instructions are given by the Engineer – in Charge
B. PROJECT ENGINEERS (Party – II)
• Shall supervise the Construction activities
• Shall provide approved construction drawing to
the Contractor before start of work.
• Shall use only OK cards for recording all
observations before or during execution.
• AEE / DEE / EE of both Construction and Quality
Control Divisions shall inspect and accord
approval to start the work on OK Cards.
• Project Engineers shall conduct independently
Quality Tests using the contractor’s infrastructure.
• Officers shall inspect and record the observations /
instructions in the Communication Register.
• All OK cards are initiated by Project Engineers which
shall be preserved till the completion of work.
• Engineers shall verify the OK cards to ensure
contractor's compliance to the corrective action
before release of bill.
C. CONSULTANTS (PARTY – III)
• Will check the Work Programme and suggest
suitable modification if needed and send it to the EE
and the contractor.
• Shall inspect important work sites before work
commences and record the observations in the OK
card (such as foundations, reinforcement etc).
• During construction, conduct Quality Test to an
extent of 10% and maintain the record. Shall
witness 10% of the Tests conducted by the
contractor. Before conducting Test shall inform
project Engineers (Construction & Quality Control).
• Shall issue inspection note from time to time
and record deficiencies in Communication
Register and verify compliance there of .
• Shall organize pre – construction meeting with
engineers of Department and Contractor and
explain the preventive measures.
• On job training also shall be organized and issue
training hand outs.
• Shall maintain Daily Activity Report, and submit
to the Project Engineer.
• Shall review designs and drawings to ensure the
construction is as per specifications
• Shall review the equipment available with the
contractor and verity caliberation and testing
personnel about adequacy as per agreement
• Shall conduct tests periodically on input
materials
• Shall submit all documents to the EE, SE, CE and
Project Director Periodically
• Shall also review the Contractor’s Resource
Planning to cope with the work Programme.
GENERAL DEFICIENCIES – PREVENTIVE
MEASURES.
A. Embankment :
i)
ii)
iii)
iv)
v)
vi)
Inspection of borrow area – testing for suitability
No over Wetting (not more than 2% of OMC)
Over sized stones (more than 7.5 cm) be removed
No roots and other unwanted material
benching of slope while increasing the width
Sub-grade preparation-measured up to 15 to 25
cm
vii) Proper spreading of soils in horizontal layers (not
more than 20 cm thick).
B. C C Lining :
i) Tested at Batching plant – Gravitational
Measurement.
ii) Fine aggregate should be hard, strong and
clean.
iii) Coarse aggregate should be free from
unwanted
material and should not be flaky
and elongated.
iv) Concrete should not be poured from a
height.
v) Curing
VI) C C CUBES
for
1 to 5 cu.m.
1 to for
5 cu.m.
1 set
(3 cubes)
1 set (3
cubes)
to 15 cu. m.
6 to 15 cu.6m.
2 sets2 sets
16 to 30 cu.m.
16 to 30 cu.m.
3sets 3sets
31 to 50 cu.m.
31 to 50 cu.m.
4 sets4 sets
and50above
and above
cu.m.50 cu.m.
additionally
additionally
1 set
for every
1 set for
every
50Cu.
VII) MIXING
20 to 30 revolutions
3 or more cu. m….2 1/2 mts
2 cu.m . . . . . . . 2mts
1cu.m . . . .. . . . . 1 1/2mts.
REGISTERS FOR QA AND QC
1.
2.
3.
4.
5.
Register of Bench Marks
Mark out Register
Material O.K. Register
Register of Foundation
Register of placement of Concrete
6 . Register of placement of Reinforcement
7. Register for Embankment Placement
(Roller Passes, Moisture Content, Proctor’s
Density etc.
8. Site Order /Communication Register
9. Cement Day Book.
THANK YOU
a) Registers:1. Site order.
2. Register of Bench Marks
3. Material O.K. Register.
4. Register of foundations.
5. Register of placement for concrete,
Embankment, Reinforcement and
other test reports.
6. Register of test reports of compressive
strength of concrete specimens
7. Cement day Book.
b) O.K. Cards for Big Structures and Heavy
Embankments:
1. O.K. card for cast-in-situ concrete
lining.
2. O.K.card for Earthwork Embankment.
3. O.K. card for grouting.
4.O.K. card for structural concrete work.
• AE/AEEs have to check pre levels and final
levels.
• For measurements recorded by E.P.C Agency,
D.E.Es to test check measurements spread over
the entire work. E.Es/S.Es to check measure as
per Codal provisions and rules in vogue.
• The measurement records have to be
maintained by E.P.C. Agency and finally handed
over to the Engineer-in-Charge
• The observations made by Third party
Quality Control, Department Quality
Control Staff have to be invariably
complied with before the next bill for
payment is presented. To this effect
certificate has to be recorded by E.P.C.
Agency and countersigned by the field
Engineers.
• Under E.P.C. System of contract,
fortnightly Management Meetings with
E.P.C. Agency by the Superintending
engineer shall invariably be convened
to discuss the Quality Assurance
Aspects and record the Minutes of
Meeting regularly.
QUALITY CONTROL STAFF.
• Shall verify the records maintained at site by
the E.P.C agency and the Third Party Quality
Control Consultants.
• Shall check 25% of the final levels /
measurements of Earth work, revetment,
leveling, concrete, linear dimensions of
important structures, Gates etc.
• Shall associate with construction staff or
conduct independently the test with required
frequency.
QUALITY CONSULTANTS
The Third Party Quality Assurance
Consultants should posses all the testing
facilities as per Agreement and conduct
independent Testing to assure the Quality
of Work.
Quality requirements should be clear and
verifiable .
DESCRIPTION OF TASKS
• Review of Design, plans and specifications for
constructability and operability.
• Important decisions regarding Quality of
works are made during design and planning
stages. Quality Assurance during construction
depends on conformance to the design and
specifications.
• Shall Submit
Reports and Records to
Engineer – in - charge
consultant to participate in designs
review meeting with project engineers
and contractors’ representatives and
give suggestions, if any………
CONSULTANT TO PROVIDE
Services enabling the Government to ensure
best Quality of Construction in the Project by
working closely with the Field Engineers.
TASKS TO BE PERFORMED BY THIRD PARTY
Review of Designs and Drawings
HPs, Designs of Structures & Specifications and
Review of QMP of EPC Agency
• Review Contractor’s Test Data & Conduct
Tests in selected frequency
• Review of Mix Design
• NDT Data on finished items
• Non-Conformities – Corrective action
• Calibration Report
• Quality Certificate
• Inter Lab Testing
CALIBRATION OF TESTING EQUIPMENT
QA consultant to verify calibration of all their
and Contractor’s testing and measuring
equipment - reports on calibration status,
frequency of recalibration etc. to be submitted
to the Engineer-in-Charge
QUALITY MANAGEMENT SYSTEM
• Quality of the work is dependent upon the
participating constituents , some of which are
sustainable and effectively controlled while
others are not.
• The process of managing the quality is
through QMP.
QUALITY MEASURES
• Periodic inspections, testing and verification.
• Proper maintenance of records and registers.
• Undertaking quality audit and review of QMP
and QAP.
• Provide training to all concerned.
STAGES FOR INSPECTION, TESTING AND
VERIFICATION
Input Materials inspection.
During Construction Inspection
Completed work inspection.
Evaluate and establish the contractors’ Q M P
(Quality Management Plan) requirements to
see whether the Q.C organization possesses
the following standards:
1) Evaluation of Testing and Inspection
efficiency.
- Effectiveness of procedures
- Operation efficiency of Plant and
Equipment
- Adequacy of personnel and
- Progress of records
2) Evaluation of Internal assessment:
-
Information that is adequate and accurate
Effectiveness of communication and feed back of
Quality Control decisions to the operation level.
- Control overall phases of operation
3) Evaluation of overall performance of various
Project Laboratories:
- Procedures being followed
- Performance of Individual laboratories
- Inter – Laboratory testing
COMPLIANCE
Procedures and controls are of no significance
unless meticulously followed. It shall be ascertained
through.
- Inspection and visual observation (Ex: concrete
lining in place, structural concrete in place etc and
supplementing it by appropriate tests).
- Examination of O.K. Card.
- Perusal of control charts for cement and concrete
- Direct Enquiry.
VERIFICATION
Consultant shall review the facilities and staff in
labs. to determine whether
- the personnel possess adequate
knowledge of testing procedures and
- the testing and inspections are
adequate.
MONITOR CONTRACTORS PROCEDURES
FOR TESTING DEFICIENCIES TO ASSURE
CORRECTIVE ACTIONS TAKEN – QUALITY
AUDIT
• Construction
Deficiencies
and
nonconformaties.
• Report to the engineer to ensure that new
work is not placed on unacceptable work.
LABS – TEST RESULTS
Depend on
- Competency of the testing personnel
- Accuracy of the apparatus and equipment
- Maintaining special environment conditions
- Proper maintenance and periodical
calibration of testing machines
PRE CONSTRUCTION CHECKS
INPUT MATERIALS
Trained personnel with necessary equipment
to verify for required specifications and the
recommend for acceptance.
Clear GUIDELINES to be drafted for inspection
requirements, sample plans and acceptable
quality levels. Test results and certificate of
conformance to be furnished to Engineer-inCharge.
Corrective Action Notice to be issued by
Consultant when material fails to conform to
specifications
To inform the Engineer-in-Charge whether the
material is passed or failed.
QA CHECKS – ONGOING WORKS
To ensure the materials, construction works
are as per specifications of APSS and IS
codes.
Defect prevention is preferred to detection
after occurrence.
QA CHECK – POST CONSTRUCTION
Physical Measurements .
Identification of defects by both destructive
and non – destructive tests.
Classification of defects and rectification if
necessary.
CONDUCT TESTS AT THE WORK SITE
Consultants to maintain confidentiality as
regards the sample testing.
For reconciliation, the Engineer-in-Charge
discusses with consultants and contractors.
QA consultant to organize inter-laboratory
testing sample with NCCB and APERL for
establishing the competence of project
laboratories.
This should be done once in THREE months.