F B Engineering
PROJECT QUALITY PLAN
(PQP)
SUBMITTED BY: Yan Bu.
Email Address: fbengineering@163.com
Phone: +267 71 302031
NAME
DESIGNATION SIGNATURE
DATE
PREPARED BY
REVIEWED BY
APPROVED BY
CLIENT APPROVAL
Contents:
1. Abstract…………………………………………….. …...
2. Introduction………………………………………………
3. Project Scope……………………………………………
3.1 Description of work……………………………………..
4. General Background and Location…………………...
5. Project Objectives………………………………………
6. Management responsibility……………………………
6.1 Commitment……………………………………..
Page
3
4
5
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7
7
1
6.2 Planning……………………………………………
6.3 Responsibility, authority and communication….
6.4 Management Review……………………………….
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7. Project Quality Plan……………………………………
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7.1
Control of Documents……………………
7.2
Control Records…………………………..
7.3
Work Environment………………………..
7.4
Design, Drawings and Specifications….
7.5
Access Releases/Handovers…………
7.6
Excavation Permits………………………
7.7
Test Certificates……………………………
7.8
Three Phases of Inspection………………
7.9
Initial Inspection …………………………..
7.10
Follow up inspections …………………….
7.11
Quality Control Testing and verifications...
7.12
Testing ……………………………………..
7.13
Failed Testing ……………………………..
7.14
Procedures ………………………………...
7.15
Testing Laboratory ………………………..
7.16
Tests and record score …………………..
7.17
Reporting and Distribution ……………..
7.18
Survey Records……………………………
7.19
Quality Documentation………………….
7.20
Control of Non-conforming Product…….
8. Inspection and Test Plan……………………………….
9. Data pack…………………………………………………
9.1
Submittals……………………………………
9.2
Filling of submittals ………………………..
10. Handover…………………………………………………
11. Annex 1…………………………………………………………………
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1, ABSTRACT
We take this opportunity to introduce ourselves as the leading Mechanical and Structural
Fabrication and Erection Company in Botswana, with a fully-equipped factory with a total build up
area of 4000 m2.The factory is equipped with modern and advance technological facility for the
manufacturing of steel structures. We specialise in the Fabrication & Supply and Erection in the
field of Mechanical and Hot Rolled Structural Engineering Services. We Can ensure timely project
completion, end-to-end quality management and budget control.
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Our every employee believes value engineering is an important part of our work, and we provide
Solutions, not just products. Our teams of qualified, experienced engineers and technicians can
create and build to client specifications, whatever the challenge. Our clients are ensured the highest
levels of product quality and workmanship including on-time completion.
Our mission is to provide high quality service/ product combined with trusted client partnership,
and to maintain high health and safety levels and solutions to the client’s needs.
OUR VALUES
• Quality and safety first
• Monitoring continuous improvement through learning and development
• Innovation and creativity in solving problems
• An empowered, committed and motivated workforce
WE OFFER EXPERTISE AND SERVICES IN THE FOLLOWING AREAS OF WORK.
• Fabrication of Warehouses and Shades.
• Fabrication and erection of steel infrastructure of Power/cement plants.
• Heavy structural girders for Bridges and Towers.
• Formwork.
• Site erections of steel structures.
2.
INTRODUCTION
This document fulfills the requirement of a quality plan as required for the execution of the
fabrication, and Erection of Structural Steel Work for different projects.
a. All processes and their application throughout the organization are identified.
b. Measurable objectives are identified according to organizational, quality, statutory &
regulatory, and customer requirements.
c. The sequence and flow of each process is identified and the criteria and methods for
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effective operation and control formalized.
d. Processes are monitored on a regular basis, their performances measured and the results
analyzed to ensure objectives are met
e. A Quality Management System is developed and is project specific as outlined in the tender
documents. Where and when necessary, external services can be sourced on a subcontract basis.
f. For these services, it remains the responsibility of F.B Engineering to comply with the
projects specification and these sources are subject to our Quality Management System in place.
3. SCOPE OF WORK
Structural steel fabrication and installation, including below details
 Production of shop drawings (Detail Engineering)
 Production of Erection Drawings.
 Supply of structural steel as specified.
 Supply of roofing materials.
 Fabrication of Steel Works
 Painting of fabricated steel works.
 Transportation of steel to site.
 Organizing route permits and clearances of material to be delivered to site.

Installation (Steel Erection)
 Roofing.
4. GENERAL BACKGROUND & LOCATION
Different project around Botswana
5, PROJECT OBJECTIVES
The Project objectives are derived from the following sources:
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
Contract requirements.

Bill of Quantities

Project Program

Compliance with Specifications and Standards

Compliance
with
Statutory
and
Regulatory
requirements

Effective application of the ITP and completion of
records

Safety Objectives

Formulated from risk identification and preventive
actions.

Management Reviews.
6, MANAGEMENT RESPONSIBILITY
6.1 Commitment.
F.B Engineering management shall ensure commitment to the provision of Quality System
compliance, in the provision of contract deliverables. Through communication, management
reviews and the provision of suitable resources, the F.B shall continue the improvement of services.
6.2 Planning
All project activities shall be detailed on a Project compliant schedule including all critical path
items, start and completion dates. A project QA plan with reference to this overall program will be
made available.
6.3 Responsibility, authority and communication.
Management shall appoint responsible personnel, with the necessary authority, enabling
communication at all levels as required per the contract.
6.4 Management Review
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Constant ongoing review of commitment and works completion shall be maintained per senior
management
so
as
to
provide
client
feedback,
process
performance/conformity
and
recommendations.
The management review team and responsibilities will be as follows:
i)
Site Manager – responsible for all site planning, control
ii)
General Foreman – responsible for the execution of site works
iii)
Quality Control Engineer – responsible of quality of materials, works and procedures
iv)
Safety Manager – in charge of all site safety
7, PROJECT QUALITY PLAN
7.1 Control of Documents:
Contract documentation relating to Contract, General/Specific contract correspondence,
Planning/Programming, Design, Purchasing, Receipt of Materials, Storage, Issue of Materials and
Installation shall be maintained per the Contract so as to provide evidence of commitment to
Contract, Specification and Standard, wherever is applicable.
7.2 Control Records:
Records established as per the relevant Method Statements providing evidence of conformity shall
be collated and bound in the related Data Books, for presentation on completion of works.
7.3 Work Environment.
F.B Engineering through its organizational structure shall ensure conformity to all environmental
issues per the contract, land/ local authority laws and local community considerations.
7.4 Design, Drawings and Specifications.
F.B Engineering shall receive and review all client supplied design and drawings, responding and
communicating acceptance or otherwise as required per the correct channels. F.B Engineering shall
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ensure all sub-contractor design and drawings are processed in accordance with the project
requirements. Registration of transmittals shall be maintained for record and compliance.
7.5 Access Releases/Handovers
F.B Engineering shall always apply for permission for site handover before moving in to any new
area as provided for by the Contract. The application should be sent in such a reasonable time to
avoid delays to the works.
7.6 Excavation Permits
Whenever F.B Engineering wants to do any excavation, the Company shall apply for a permit to
carry out this activity, before any excavations can commence and to be approved by HPJV.
7.7 Test Certificates
As a contract requirement F.B Engineering shall maintain records of all completed tests.
A set of prints of the general arrangement drawings, fabrication and
shall be maintained. Test
registers with date of test, date of Fabrication, and drawing number will also be maintained. All
weld test to be witnessed by Client’s Quality Department (Witness point on QCP/ITP)
F.B Engineering to submit Compliance Test Certificates of supply from suppliers and from testing
Laboratories.
7.8 THREE PHASES OF INSPECTION
Preparatory Meetings shall be performed prior to the beginning of any major definable feature of
work. A meeting shall be held for each crew performing such feature or when members of the crew
change. Preparatory Meetings shall be conducted by the Quality Control Manager and/or designee
after a complete review of all applicable blueprints, specifications, shop drawings and related
submittals has been made. A Preparatory Meeting Agenda (refer to Appendix C, Forms) shall be
completed for each definable feature of work and distributed at the meetings. At the Preparatory
Meeting, the Superintendent and Foreman (involved in this phase of construction) shall coordinate
with Quality Assurance, Quality Control and Safety personnel and shall introduce their plan for
accomplishing the work. The Client shall be notified at least 48 hours in advance of the Preparatory
Meeting. The following items shall be discussed at such meetings:
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a. Review of the applicable specifications.
b. Review of applicable blueprints and shop drawings.
c. Review of related submittals and a check that all related submittals, shop drawings and
materials have been tested (if applicable), submitted and approved.
d.
Review of the detailed sequence of the execution of the work.
e. Discuss required testing and frequency.
f.
Review provisions to ensure controlled inspection and testing.
g. Examination of the work area to ensure that all required preliminary work has been
completed and is in compliance with the contract.
h.
Examination of the related material, review of the Receiving Inspection Reports and
verification that the items received are in compliance with the contract and are properly
stored.
i.
Review of the Activity Hazard Analysis Report to ensure that all safety precautions are met
and the required safety equipment has been purchased and is available.
j.
Review and document the workmanship expected for the definable feature of work.
k. Meeting Minutes shall be recorded and distributed within 48 hours of the conclusion of the
meeting.
7.9 INITIAL INSPECTIONS
Initial Inspections shall be performed at the beginning of any definable feature of work and must be
repeated at any time new workmen or new crews are assigned to the work or if the required
standard of work is not being met. The Site Engineer shall be notified at least 48 hours in advance.
The same personnel who attended the Preparatory Meeting shall also attend the Initial Inspection.
These should include: the Site Manager and Foreman, Safety Personnel and the Quality
Assurance/Quality Control Staff. The following shall be accomplished during such meetings;
a. Review the minutes of the Preparatory Meeting and verify that the work complies with the design
documents; i.e., submittals, specifications, blueprints and/or shop drawings.
b. Resolve all differences.
c. Verify adequacy of inspection and testing.
d. Establish a level of workmanship and verify that it meets the requirements.
e. Check Safety and review the Activity Hazard Analysis Reports.
f. Provide documentation of the previous inspection of the work area.
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g. Re-examine the work area for compliance.
h. Meeting minutes shall be recorded and distributed within 48 hours of the conclusion of the
meeting.
Note: Preparatory Meetings and Initial Inspections are intended to prevent non-conformances from
occurring.
7.10 FOLLOW-UP INSPECTIONS
Follow-Up Inspections shall be performed daily to ensure that the control established during
Preparatory Meeting and Initial Inspection continues to provide a product that conforms to the
contractual requirements.
a. Construction activities shall be inspected by Quality Control in accordance with Quality Control
Procedures. Forms for various activities (refer to examples in Appendix C, Forms) shall be filed and
attached to the Contractor’s Quality Control Report.
b. Installation and testing activities which do not comply with the requirements shall be documented
on a Non-Conformance Report (NCR), Refer to Section 8 for Non- Conforming Items.
c. Modifications, repairs and/or replacement of materials and/or parts performed subsequent to Final
Inspection shall require re-inspection and/or retest to verify acceptability. Inspection and testing
documents shall be filed and maintained in accordance with Section 5, Reports and Records and
shall be available for review by Client
Signatures of acknowledgement show that the Three Phases of Quality Control Inspection Program
is understood and will be followed.
7.11 QUALITY CONTROL TESTING AND VERIFICATIONS
To ensure that tests are adequately planned and that the necessary testing procedures are available to
conduct the test in a satisfactory manner. This procedure established the methods to be used when
conducting tests listed in the specifications. Test reports shall be filed and logged accordingly.
7.12 TESTING
A list of tests required, to verify that control measures are adequate, shall be delineated in the
specifications and/or determined upon the completion of the design. The list shall include the test
name, specification paragraph, feature of work to be tested, the test frequency and the organization
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that will perform the test. A Quality Control Representative (QCR) shall notify the Site Manger of
the proposed test 48 hours in advance. The QCR shall witness the test with the appropriate
organization and/or individual qualified to perform the designated test(s).
The list of test will be not being limited to the following.
1. Weld Test (Magnetic Particle Inspection and Dye Penetration Test and or Ultrasonic)
2. Material Test (If required)
3. Paint dry and Wet Film Test.
These entire tests will be taken under the supervision of the Quality Control Manager or his
Assistant and the result will be submitted to the HPJV for the review and further action.
7.13 FAILED TEST
Failing tests shall be cleared by one of the following methods:
a. Re-test – Retest if there is any doubt that the first test was not adequate.
b. Re-work – Re-inspect and retest.
c. Failed Material – Remove, replace re-inspect and retest.
7.14 PROCEDURES
a. The Quality Control Manager and/or staff member shall review the testing requirements to insure
that the planned test is in accordance with the design documents: i.e., plans, specifications, shop
drawings and/or other documents.
b. Instruments used for testing shall be calibrated in accordance with established calibration
procedures. Specialists experienced in such work shall perform the calibration.
c. Technicians performing tests shall provide copies of calibration certificates and their field notes
and reports to the Quality Control Manager.
d. Quality Control shall witness all required tests delineated in the design documents (blueprints,
specifications, shop drawings, etc.).
e. The Corps shall be notified of all scheduled tests.
f. Test reports, when completed, shall be attached to the Contractor’s Quality Control
Report and submitted to the HPJV.
7.15 TESTING LABORATORY
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The Testing Laboratory shall conduct all required tests for welding, etc in an independent testing
laboratory. The testing laboratory shall work under the direction of the Quality Control Manager.
The contractor must select a certified laboratory. Where applicable, explain verification tests for
equipment and mechanical commissioning.
7.16 TESTS AND RECORDS SCOPE
This section establishes a system for the control of documentation and records which provide
objective evidence of the quality of items and activities performed in accordance with the
programmatic requirements. The Quality Control Manager is responsible for the control, review,
verifications and maintenance of the documentation delineated in the specifications.
F.B Engineering shall maintain a record of calibration certificates of equipment and plant as
required by the Contract or as requested by the Engineer. Survey and Laboratory equipment in
particular should have valid certificates. All valid Calibration Certificates to be reviewed and
approved by HPJV before commencing of any works and to be registered and controlled.
7.17
REPORTING AND DISTRIBUTION OF REPORTS
1, After reviewing reports, including subcontractors’, the Quality Control Manager or his
representative shall submit the documentation to the Site Manager.
2, All inspections and testing shall be summarized and recorded in a Contractor’s Quality Control
Report (CQCR). A copy of the CQCR shall be sent to the Project Manager’s, Head of Quality
Control.
“Original” reports shall be retained by the Quality Control Manager. Field notes,
inspection forms, and test reports shall be filed and available for review by the Client
3. The Contractor’s Quality Control Report shall include the following:
a. Contractor and subcontractor area of responsibility.
b. Working, idle and down time hours for equipment.
c. Work accomplished each day, indicating the location, activity and by whom.
d. Laboratory test reports, including the test results (passing or failing), location of test and
specification reference.
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e. Deficiencies and corrective actions.
f. Material received on site.
h. Safety violations and corrective action implemented.
7.18 Survey Records
It is the CSC understanding that all surveyor records should be maintained. The Contractor surveyor
will agree with the Engineer surveyor on all recordings, before commencing of next stage of
process which will be a Hold Point on the ITP
7.19 Quality Documentation.
The following is a list of activities which may require method statements.




Setting out.
Material handling, storage and transportation.
Fabrication.
Erection.
A standard format is used for all method statements and a register will be kept throughout the
project. New and altered method statements will be reviewed within management before
submission to HPJV for approval. The procedure for Control of Documents will then be followed.
7.20 Control of Non-conforming Product.
Where evident, non- conforming products, items or processes will be quarantined with specific
marking, until corrective action has been satisfactorily performed.
On completion of the Remedial action on the Non-Conformance the Client or Client Representative
will be requested to inspect that Area and upon approval and acceptance of the remedial
implemented the close-out report will be completed and the non-conformances will be closed out.
8 INSPECTION & TEST PLANS
The Inspection and Test Plan identifies the items of materials and work to be inspected or
tested, by whom and at what stage or frequency, as well as Hold and Witness Points, references
to relevant standards, acceptance criteria and the records to be maintained. Inspection and Test
Plans shall be properly implemented, to ensure that, and verify that, work has been undertaken
to the required standard and requirements, and that records are kept.
When all activities are completed and the relevant interventions auctioned, the Data Pack is
completed and submitted to the client.
Once completed, all Inspection & Test Plans are to be recorded on a register.
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9 DATAPACK
This will contain all documentation as agreed with Client
9.1 SUBMITTALS
All submittals shall be reviewed, certified and managed by the Quality Control Department. Copies
of the manufacturer’s data (material, equipment, fixtures, etc.), including catalogue cut-sheets
showing dimensions, schedules, operation and maintenance manuals and any other relevant
information shall be submitted in the English language. Submittal quantities shall be determined by
the HPJV at the Pre-Construction Conference. The QC Manager will be the authorized submittal
reviewer and testing lab personnel (both on site and factory)
9.2 FILING OF SUBMITTALS
Submittals (Material, Design, Data, Samples, Shop Drawings, etc.) shall be filed according to the
specification section number and paragraph number in a secure place for reference and
coordination. Colour and mock-up samples shall be maintained in a secure place, at the job site, for
comparison with the finished product. A tag or sticker identifying the submittal number and the date
of approval shall be attached to the sample. When a colour or mock-up sample is not approved, it
will have a “Rejected” tag or sticker attached to the item and it shall be removed from the job site
(if requested), and a copy of the record will be maintained along with a photograph of the
disapproved item. When submittals are not approved or incomplete, they shall be returned to the
supplier and/or sub- contractor with comments. They shall be corrected and re-submitted for
approval (See below, Submittal Flow Chart). Submittal Register The Submittal Register shall be
maintained by the Submittal Coordinator. Revised copies of the Submittal Register shall be
provided to the HPJV on a monthly basis.
10 HANDOVER
The Hand Over of the Works will be as per Client Hand over Procedure.
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ANNEX
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QUALITY CONTROL (QC) MANAGER DUTY AND APPOINTMENT
The Quality Control (QC) Manager, will be responsible for overseeing overall implementation of Quality
Control Plan and will coordinate all project testing, inspections and reporting matters directly with the
Project Manager. The QC Manager and all workers have the authority to intercede directly and stop work
due to any unsafe work practices or site conditions.
DUTIES
• Preparation, approval and implementation of the QA&QC Plans
• Verification of Material as per project Specifications
• Inspection of delivered materials as per Project Specs and Relevant standards
• Co-ordination with Independent labs for conducting different test such as: tensile tests, soil test,
compression test, etc. according to project specifications.
• Ensure that all materials and construction are in accordance with the requirements for the completeness,
accuracy, constructability in compliance to the requirement to Project scope.
• Documentation for material and administrative approvals and backups.
• Carry out and participate in weekly progress and QC Meetings
• Manpower adequacy checking as per scheduled activities
• Supervision of Quality Inspectors for different Inspection activities.
• Inspection of Civil works executed by Sub-Contractors
• Ensure to carry out all work in a safe manner in accordance with site rules and regulations.
• Contributed to effective team works and team building by working closely with other team members.
• Execute daily operations of construction activities.
• Carry out quality control checks as defined on quality plans as directed by Project Manager.
• Witness critical installation activities as defined on contractor's quality plan.
• Ensure that works are coordinated in an effective manner so that programmed objectives are achieved
. • Estimate quantities and cost of materials, equipment, and labor to determine project feasibility.
• Provide technical advice regarding design, construction, and program modifications and structural repairs
to industrial and managerial personnel.
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LETTER OF AUTHORITY.
Project: ______________________________________
Location: _____________________________________
Contract No.: _________________________________
Subject: Letter of Authorization
From: Managing Director: Yan Bu.
To: QC Manager_______________________________
Mr. Engineer, _________________________________ This Letter of Authorization outlines your
responsibility as our site Quality Control Manager for the project referenced above. As the site Quality
Control Manager, you shall report directly to the Project Manager. You shall review the specifications,
amendments, plans and drawings in their entirety and implement the Quality Control Program. The
quality control program encompasses three phase Inspection: Preparatory Meetings, Initial and FollowUp Inspections. All inspections and testing shall be recorded in the Quality Control Report and
submitted to the Project Manager of the official work day. Test reports shall be submitted no later than
three official work days after the test was performed. You and/or your staff shall be responsible for
reviewing specifications, submittals, as-built, plans and shop drawings for Compliance to the contractual
requirements. Additionally, this all applies to all subcontractors documents. You and/or your staff shall
make daily inspections to ensure that the workmanship and materials used in the construction of the
project are in compliance with the plans, drawings and specifications. You are authorized to stop work
that does not comply with the plans and specifications. You and/or your staff shall witness all tests
required by the specifications and coordinate such tests with the HPJV. You and your staff must
document all non-conforming conditions, items and/or workmanship noted, and will constantly monitor
and alert Safety Staff Members to safety violations. If at any time you should require assistance with the
implementation
of
the
quality
control
program,
please
contact
the
Project
Manager.
____________________________
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QC DAILY REPORTS
DAILY QUALITY REPORTS
CONTRACTORS QUALITY CONTROL REPORT (QCR)
DAILY LOG OF ACTIVITIES.
REPORT NUMBER
Page 1 of
Date
Project
Contract Number
QC NARRATIVES
Where there any delays in work progress today?
Verbal instructions given by HPJV/ CSEC:
Did anything develop that may lead to change order claim?
Activities in Progress:
General Comments:
Safety inspections/ Safety Meetings:
PREP/INITIAL DATES (PREPARATORY AND INITIAL DATES HELD AND ADVANCE NOTICES)
CONTRACTOR'S QUALITY CONTROL
REPORT.
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WEEKLY QA/QC MEETING
MINUTES.
Date
Time
HPJV
Engineer
Structural
Company
ITEM
No.
Description
of
Item Discussed
Location
Steel Subcontr
actors
Action
Date
Actio
n By
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