Quality Assurance Quality Control Manual.pdf 6o6554

RUIDP (ADB LOAN NO: 1647-IND)

1

QUALITY ASSURANCE/ QUALITY CONTROL MANUAL

INTRODUCTION

This section of the Quality Assurance/Quality Control Manual presents the Project’s background, defines quality-related , and gives an outline of the Manual.

1.1

Background

The Government of Rajasthan has undertaken the implementation of the Rajasthan Urban Infrastructure Development Project (RUIDP, the Project) during the period from 1999 to 2004 with assistance from the Asian Development Bank. The project is being implemented in the towns of Jaipur, Jodhpur, Ajmer, Kota, Udaipur and Bikaner. Infrastructure facilities to be provided include water treatment plants, supply mains and distribution systems, sewage treatment plants and sewer systems, roads and bridges, storm water drainage, truck and bus terminals, solid waste management systems, community buildings, truck and bus terminals, and other schemes. The Project Management Unit and the Project Implementation Units have been setup. The Project Management Consultants and Design and Supervision Consultants have been appointed and have started functioning from months of June and July 2001 respectively. The Project is unique in its nature and complexity, characterized by its spread across six locations, estimated over 150 construction or procurement contracts of different nature, and participation by multiple agencies. In view of this complexity, it is essential and important to put in place a comprehensive, consistent, and common system for quality assurance and control during implementation. This document has been prepared with this purpose in mind.

1.2

Quality Definitions

Quality is the totality of features and characteristics of a product or service that bear on its ability to satisfy a given need. The term 'given need', in case of project works, can be interpreted as the functional requirements. The quality of outputs is always agreed upon between the supplier and the client (in project works, contractor and the owner), and the quality objective must be to achieve zero defects. It can be made possible only by ensuring the quality at all stages of project works. The following are some definitions pertaining to quality and how to achieve it: •

Quality: Conformance to requirements.

•

Quality Control (QC): The operational techniques and activities (such as reviewing, checking, inspecting, testing, etc.) that are used to fulfill requirements for quality.

•

Quality Assurance (QA): The planned and systematic actions necessary to provide adequate confidence that the work will satisfy quality requirements.

•

Quality System (QS): A set of documented processes, which seek to provide confidence that the project outputs will fulfill the functional requirements. The Quality System should encom the organization, responsibilities, human resources, materials, equipment, processes, inspections, testing and other parameters of the project. A key element of QS is the QA/QC Manual.

•

Quality Surveillance: This normally covers two aspects: •

At the project level, a review to ensure that the quality practices are implemented and documented in relation to the quality system; and

•

At the contract package level, inspection and testing to ensure that the works executed meet the required quality standards.

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1.3


QA/QC Manual

This QA/QC Manual focuses on the implementation activities of the project following contract award, and primarily on supervision and quality control of construction works. Other aspects of project implementation are also covered but in less detail. The QA/QC Manual is intended to be used primarily by the project staff of the PIUs and the Design and Supervision Consultants. The QA/QC Manual for the Project does not attempt to suggest technical specifications, since these are stated in the contract documents. Its aim is to ensure that the works are executed as per specifications, i.e. it is looked at as a means to achieve the end results. Quality control and test results shall be interpreted as applicable for different packages, in accordance with the contract conditions. The subsequent sections of this Manual are as follows: •

Organization, Responsibilities and Authorities

•

Design Control

•

Construction Quality Control – General

•

Control of Materials and Equipment Components

•

Control of General Civil and Structural Works

•

Control of Road and bridge Works

•

Control of Pipeline Works

•

Control of Electro-mechanical Works

•

Document Control

•

Reporting

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2


ORGANIZATION, RESPONSIBILITIES AND AUTHORITIES

This section of the QA/QC Manual describes the organizational arrangements for project implementation and outlines the responsibilities of each organization.

2.1

Project Implementation Arrangements

a) As agreed between the Government of Rajasthan and the Asian Development Bank, the Rajasthan Urban Infrastructure Development Project (RUIDP) will be executed through the Project Management Unit (PMU) of the RUIDP. The State has appointed a Project Director for the PMU, and the PMU has the overall responsibility for coordination and management of the Project activities, including Project design, implementation, budgeting and financial planning, benefit monitoring and evaluation, socioeconomic surveys, environmental assessment and protection, institutional and policy development, community participation and coordinating the work of all consulting services under the Project. b) Project Implementation Units (PIUs) have been established in each of the six cities to the PMU in its works. They have the primary responsibility for planning and implementing all the Project components in time, within cost estimates, and to the quality standards specified in the contract documents within their respective areas. c) An Empowered Committee under the Chairmanship of the Honble Minister Local Self Government of Rajasthan (Minister LSG) has been established to enable making speedy decisions regarding all Project components. The Project Director is the Member Secretary of the Empowered Committee, which has been given full authority regarding all Project implementation aspects including awarding of contracts. d) A City Level Committee has been constituted in each city by the Empowered Committee to periodically review the project and assure coordinated work within the city. The committed is headed by the District Collector except in Jaipur where it is headed by the Secy. UDD. e) The Government has formed a Technical Committee for according technical sanction to the estimates. It is however proposed to delegate authority to the PMU for issuing technical sanctions up to a limit of Rs. 1.0 crores. f)

For prequalification of contractors Evaluation Committees has been formed for evaluating the Prequalification documents submitted by contractors and to assist the EC finalize the prequalified contractor list. Similarly in order to facilitate approval of other tenders, the Empowered Committee has formed Tender Evaluation Committees (TEC) and Tender Approval Committees separately for Local level Civil Works < Rs. 1.0 crores and works of LCB. These committees will evaluate and approve tenders up to their delegated powers.

g) All the activities proposed under the Project are in jurisdiction of an existing department of the State (PHED, PWD, JDA, UITS Municipal Corp., etc.). These departments are termed as line department for the work. They have assisted in shaping the Project and will have an important role of providing the details of existing status, related studies and reports available and in finalizing the works to be taken up. They will also be associated in detailed work planning and will ultimately take over the assets after the works have been completed. h) The PMU has recruited an International Consulting Agency M/s Louis Berger International, Inc. as Project Management Consultant (PMC). They are based in Jaipur. They are responsible for assisting the PMU in implementing, managing and monitoring Project activities, recommend ways to accelerate Project implementation.

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i)

The PMU has also recruited three Design and Supervision Consultants (DSC) as below:

j)

M/s Shah Consultants for Jaipur

k) M/s Consulting Engineering Services for Kota, Ajmer and Udaipur l)

M/s TCE Consulting Engineers for Jodhpur and Bikaner.

m) The DSC are responsible for all Project activities in the respective cities along with the PIU. This includes identification of the work packages, design, tender document preparation, evaluation and implementation. They are also responsible for quality assurance. n) It is also proposed to engage a separate NGO for carrying out the Community Awareness and Participation Program. A City Liaison Officer (CLO) responsible for maintaining liaison in the city and the Project will be deputed in the PIU of each City. o) There is an overlap in the responsibilities as generally elaborated above. The details of the individual responsibilities of each wing related to various activities are laid down as below to avoid any misunderstanding. The list of responsibilities as enumerated below may all not appear to be of direct bearing on the quality, do contribute to clarity of responsibility and hence help organize the works better. This is only to facilitate smooth functioning and is not meant in anyway to dilute the responsibilities and authority various wings have in their respective jurisdiction. Table 2.1: Responsibilities of Key Agencies S. No. 1.0 1.1

1.2

1.3

1.4

2.0 2.1

TASK

RESPONSIBILITY

Unit

APPROVAL OF WORKS istrative and Financial Approval of the Project

Submission

PIU/ PMC/PMU

Approval

EC

Identification of detailed work packages with preliminary estimates at city level for istrative approval

Compilation

DSC/PIU

Feasibility and estimation

DSC/PIU

Approval of Work Packages

Review

PMC

Approval

PMU/EC/ ADB

Submission &review

PIU/ PMC/PMU

Approval

EC/ADB

Preparation

DSC/PIU

Check review & recommend

PMC

Approval

PMU/TC

Subsequent changes in the list of works

TECHNICAL SANCTION Collection of data, necessary surveys and investigations and preparation of detailed Engineering design, drawings and estimates (above Rs.1.0 crore)

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2.2


Collection of data, necessary surveys and investigations and preparation of detailed Engineering design, drawings and estimates (below Rs 1. 0 crore)

3.0

CONCEPT DESIGNS AND PARAMETERS

3.1

Concept designs after preliminary investigation including different alternatives and proposed design parameters for all major works and specialized works.

3.2

Preparation of typical drawings for the Project

4.0

TENDER DOCUMENTS

4.1

Prequalification Documents for LCBs

4.2

Tender documents for local works <= Rs. 1.0 crores, ICB, LCB and material procurement

5.0

TENDER AND AWARD

5.1

Prequalification of contractors

Preparation

DSC/PIU

Check, review and recommend

PMC

Approval

PMU/TC

Preparation

DSC/PIU

Check, review and recommend

PMC

Approval

PMU

Primary

DSC

Secondary

PMC

Preparation,

PMC

Review and recommend

PMU

Approval

EC/ADB

Preparation

DSC/PIU

Evaluation

TEC

Review

PMC/PMU

Approval

TAC

Notice inviting offers

PMU

receiving offer

PMU

Evaluation and Comparative statement

PMC/ Evaluation committee

Review

PMU

Approval

EC/ADB

(PAGE 5)


5.2

5.3

5.4

5.5


Tenders for works with estimated value < = Rs. 1.0 crores

Tenders for LCB civil works more then Rs. 1.0 crores and less then $ 5.0 million.

Tenders for civil works more then $ 5.0 million ICB packages

NIT /receiving tenders

PMU /PIU

Comparative statement

DSC/PIU

Evaluation

TEC

Bid examination

PMC/PMU

Approval

TAC/ADB


PMU/ PIU

Comparative statement

DSC/PIU

Bid examination

PMC/PMU

Evaluation

TEC

Approval

TAC/ADB


PMU

Comparative statement & examination

PMC

Bid examination

PMU

Evaluation

TEC

Approval

EC/ADB

International shopping for items less then $ 1.0 million, NIT /receiving ICB for grater than $ 1.0 million tenders

PMU

Comparative statement &examination

PMC

Bid examination

PMC/PMU

Evaluation

TEC

Approval

TAC/EC/ ADB

5.6

Issue of Work Orders, g of Agreements and upkeep of original contract documents for all works and local procurement.

PIU

5.6

Issue of Purchase order, g of agreement and upkeep of original contract documents for centralized procurement.

PMU

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6.0

CONTRACT IINISTRATION AND CONSTRUCTION SUPERVISION GENERAL

6.1

Primary overall istration and management of the contracts including interpretation of the technical specifications and other contract documents as may be Secondary required;

6.2

Review and revise construction drawings as may be necessary from time to time, either to suit site conditions, changes in construction strategy or changes in design, and provide clarifications / explanations on the designs and drawings to the contractor.

PRIMARY SECONDARY

Submission

DSC /PIU PMC/PMU PMU/PIU PMC/DSC

DSC/PIU

Review, check and PMC recommend Approval

PIU/PMU

6.3

Review, check and DSC/PMC review and recommend acceptance or modification of the construction drawings and designs prepared by the recommend contractors for the turnkey contracts PIU Approve

6.4

giving level and layout for those items of work where dimensional accuracy has a direct bearing on the quality and performance of the finished work to ensure conformity with the quality requirements stipulated in the contract;

6.5

Primary

DSC

Secondary

PIU

Primary Assess the adequacy of the inputs such as materials, labor and equipment provided by the contractor and Secondary the construction methods proposed and ensure that they are satisfactory with reference to the technical requirements, implementation schedule, environmental aspects, and safety of the works, project personnel, and general public welfare. Inform PMU and PIU, in writing, of any deficiencies found, and recommend any remedial actions which are required to be taken

DSC PIU

proper inventories and s are maintained of all dismantled materials, particularly for those materials which are to be re-used in the works;

Primary

DSC

Secondary

PIU

6.7

the work site is maintained in a neat, orderly and safe manner;

Primary

DSC

6.8

any inconvenience to the public is minimized; and Payments are made to the Contractor in a timely manner.

Secondary Primary

PIU PIU

Secondary

DSC

6.6

6.9

Necessary assistance to solve any contractual dispute Primary and sort out issues requiring external interdepartmental coordination, which has an overall obligation to ensure Secondary the successful implementation of the project, works.

6.10 providing continuous on-site supervision during construction and ensuring the safety of the works; 6.11 supervising and monitoring the progress of the works, including identifying cause(s) of delays, determining remedial actions to correct such delays, and issuing instructions to contractors;

PIU/PMU DSC/PMC

Primary

DSC

Secondary Primary

PIU PIU/PMU

Secondary

DSC/PMC

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6.12 the contractor fulfills his obligations under the contract and satisfactorily completes all contractual obligations and complies with all applicable statutes, regulations, contract conditions, specifications and instructions;

Primary

PIU/PMU

Secondary

DSC/PMC

6.13 the contractor completes the work within the scheduled Primary time Secondary 6.14 ensuring that Site Order Books, Daily Work Records, Primary Labor, Material and Machinery Logs are properly maintained Secondary

DSC/PIU

6.15 making test records and results available to the PMC/PMU for review and assessment

Primary

DSC

Secondary Primary

PIU PIU/PMU

Secondary

DSC/PMC

Primary

DSC

Secondary

PIU

6.18 ensuring that the contractor prepares and submit Monthly Progress Report in the approved format and on time

Primary

PIU

Secondary

DSC

6.19 developing and implementing efficient O&M procedures and practices for Project infrastructure ensuring the participation of Project Affected Persons (PAPs) in planning, implementation and monitoring of the slum up gradation component

Primary

DSC

Secondary

PIU

7.0

Primary

DSC/PIU

Secondary

PMC/PMU

6.16 acting on project issues and problems as they arise, and promptly issuing written instructions to the contractors to address the problems; The contractual notices can be given by the PIU only, but letters for quality and other matters can be given by DSC 6.17 ensuring that the contractor properly prepares the "As Built" drawings for the completed works;

7.1

7.2

7.3

QUALITY ASSURANCE AND INSPECTIONS

prepare a simplified Quality Control Manual for use of Primary the field staff, and assist in providing on-the-job training to PIU and Contractor staff Secondary Provide effective supervision of the works in order to ensure the quality and conformity with the standards and specifications prescribed in the contract

PMC/PMU DSC PIU

DSC PIU

Primary

DSC

Secondary

PIU

Primary Regular and frequent inspections of all work sites should be made to check the nature and quality of Secondary work being done, to the materials, equipment and labor engaged at the site, to review the quality control tests and test results, and to ensure that the work is being implemented in accordance with the approved standards and that the quality control procedures set forth under the contract are being followed. Any problems observed and recommended remedial actions are to be immediately notified to the P IU, PMC and PMU . The problems noted and actions taken or to be taken are to be recorded in the site order book and signed by DSC/PIU.

DSC PIU

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7.4


Witness all quality control sampling and testing done by the contractor. Compile and review all quality control data obtained from tests conducted by the contractor or by others and the accuracy of the test data by checking the procedures used in the field for sampling and testing of the materials and works. Carry out independent sampling and testing wherever considered necessary, or as may otherwise be required to check and the accuracy of the test results conducted by the contractor. Assess the test results and recommend on acceptance of the materials supplied and on the works completed. To ensure that proper records of the tests conducted are maintained.

Primary

DSC

Secondary

PIU

Conducting Tests

Contractor

Witness and verification JE-PIU/ Engineer DSC

100%

AE/EE-PIU/ ACM

30%

SE PIU/ CM/DyCM 5% 7.5

7.6

7.7

7.8

Periodic inspections on an as-required basis should be Primary made tly by the DSC Senior Engineer and PIU Secondary representative to inspect and accept interim work completion stages (i.e., completion of sub grade, sub base, base course, etc.) in order to permit the contractor to proceed with further works. All approvals should be entered into the site order book and signed by all parties, and no work on further stages should be permitted until the earlier stage work has been inspected and accepted. In the event that the work fails to meet the required standards, any removal and replacement or other remedial measures which may be required should be clearly explained along with a time schedule for completing such work;

DSC PIU

t final inspection(s) of the completed works of by Construction Manager DSC, PIU and contractor, preparing a statement of exceptions for any works which may remain to be completed, approving and accepting the completed works, issuing the Certificate of Acceptance and making final payment to the contractors

Primary

DSC/PIU

Secondary

PMC/PMU

inspections of the completed works, ensuring that any defects in materials or workmanship are properly identified in a timely manner, and ensuring satisfactory maintenance of the works for one year following completion as per contract

Primary

DSC

Secondary

PIU

Participate in monthly inspections and site coordination Primary meetings of PIU, DSC and Contractor for all works to Secondary review the overall progress and quality of the works, review the problems which may have arisen, the instructions which were issued to the contractor to address these problems and the contractor’s compliance with these instructions, and to agree on any further actions which may be required to be taken to improve either the progress of quality of the works. The DSC shall be responsible to prepare the minutes of the site coordination meetings in order to maintain a permanent record of all agreements reached, instructions issued and actions to be taken. (Note: The PIU will be solely responsible to issue any written instructions to the contractor.

PIU DSC

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7.9


Primary Provide certification on the quality of the works accomplished and included in the contractor’s monthly Secondary progress billings, and on its conformity to the specifications and drawings, and recommend on acceptance of and payment for the completed works. If the consultant considers that any item of work or construction material is substandard or unacceptable, recommend that such work or supply of material be deducted from the progress payment or that payment be deferred until necessary rectification’s are made by the contractor and provide a full written explanation of the deficiencies noted along with necessary ing data, including test results, to the PIU as well as to the PMU. Recommend on remedial measures to be taken to bring the substandard work up to the necessary standard

DSC PIU

7.10 following expiration of the Maintenance Period/defect liability period, inspecting the works, identifying any defects in materials or workmanship, issuing the Maintenance Certificate and releasing the security deposit or balance of security deposit following satisfactory correction of all defects;

Primary

DSC

Secondary

PIU

8.0

Proposal

DSC

Approval

PIU/PMC/ PMU

Proposal

DSC

Approval

PIU

8.1

8.2

9.0

CONTRACT VARIATIONS

Make a monthly assessment of the progress and quality of the works and recommend to the PIU on any necessary variations to the contracts, including work programs, work procedures, inputs, safety, quality, variation orders, completion dates, and/or any other matters which may affect the timely and satisfactory completion of the work. Propose and present for approval any changes in the plans which may be deemed necessary, and indicate any effect such changes may have on the contract. Assist the PIU in preparing any required variation orders and obtaining necessary approvals from the PMU and PMC prior to issuance to the contractor where required.

Examining and approval of all proposed variation Proposal orders or claims from the contractor for time extensions, extra compensation, or expenses or other Approval similar matters, preparing variation orders and obtaining necessary approvals from PMC/ PMU prior to issuance to the contractor where required.

DSC

MEASUREMENT AND PREPARING BILLS AND PAYMENTS

Preparing

DSC

Approval and Payment

PIU

PIU

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9.1


Conducting with contractor t measurement of the works in the stipulated format for payment and ensuring timely approval and payment of the contractor’s running bills The DSC & PIU will provide certification on the quality of the works accomplished and included in the contractor’s monthly progress billings, and on its conformity to the specifications and drawings. The measurements will be entered by Engineer DSC. The responsibility for quality, correct and accurate measurements is of CM or Dy CM, DSC, subject to overall control of SE PIU.

Preparation/ measurement of bills

DSC

Checking by AMC DSC & AEn/XEn PIU

30%

Checking by CM or 5% Dy CM DSC/ SE PIU Payment

9.2

9.3

Conducting with contractor t measurement of the works for payment of Final Bills after satisfactory completion of works and payment as per the works contract provisions. The DSC & PIU will provide certification on the quality of the works accomplished and included in the contractor’s monthly progress billings, and on its conformity to the specifications and drawings, and recommend on acceptance of and payment for the completed works. The responsibility for quality, correct and accurate measurement is of CM or Dy CM-DSC, subject to overall control of SE-PIU.

Record Measurement for such measurements which cannot be verified subsequently. The responsibility for quality, correct and accurate measurement is of CM or Dy CM-DSC, subject to overall control of SE-PIU.

SE PIU

Preparation/measu DSC rement of bills. Engineer & JEn PIU100% Checking by AMC DSC & AEn/XEn PIU

30%


SE PIU

Measurement and record

DSC Engineer & JEn PIU100%

Checking by AMC DSC & AEn/XEn PIU

100%

Checking by CM or 10% Dy CM DSC/ SE PIU 9.4

Preparing necessary payment release order of security and payment thereof after completion of the defect liability period as per the contract. The DSC(CM) and SE PIU will provide a certificate regarding fulfillment of conditions related to defect liability period. The responsibility for quality, correct and accurate measurement is of CM or Dy CM-DSC, subject to overall control of SE-PIU.

Preparation and verification of bills

ACM DSC & AEn/XEn PIU-100%


SE-PIU

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9.5


ing of the bills for supplies received under the material procurement packages after due inspection and checking and payment thereof. The DSC, Line Agency and PIU will provide a certificate regarding full confirmation of the goods to the specifications and being in good condition. Physical verification of all supplies by SE-PIU and CM or Dy. CM-DSC is compulsory.

Preparation and Verification of bills

DSC Engineer & JEn-PIU100%

Verification & checking by ACmDSC/ AEn or SEnPIU/ Line Department

100%

Checking by CM or 10% Dy CM-DSC & SEPIU Payment

SE-PIU

10.1 Monthly Progress report to DSC

Submission

Contractor

10.2 Preparing Monthly Progress Reports in the approved format, including physical and financial progress, problems encountered and actions taken for each city, and submitting to the PIU, PMC AND PMU in a timely manner incorporating the contractor’s report.

Submission

DSC

10.0 REPORTING

10.3 reporting to PMC and PMU from time to time regarding Submission overall physical and financial progress of work, with specific mention of problems encountered and actions Comments / Recommendations taken or remedial measures recommended, variation orders approved, anticipated slippage in any item of work, rectification measures recommended, and any specific assistance required from PIU or PMC or PMU

DSC PIU/PMC

10.4 Submission of the contract completion report summarizing the construction activities and indicating, among other things, contract changes, claims or disputes, or any other substantive matters having an effect on the cost and progress of the works and accurate and complete "As Built" drawings ( to be submitted by the contractor)for the completed works

Primary

DSC

Secondary

PIU

10.5 assist the PMU in preparing the Project Completion Report

Preparation

DSC/PMC

Review

PIU/ PMU

10.6 Monitor Progress and submit a monthly report for the Project including Physical, Financial progress of works and other components of the Project

PMC

10.7 Submit a quarterly Progress report for submission to DEA and ADB through PMU

PMC

11.0 BUDGET 11.1 Annual plan of work and forecast of funds requirement for each component of the Project for each city.

Primary

PIU/DSC

Secondary

PMC

(PAGE 12)



11.2 annual Project plan and forecast of funds requirement for the Project

Submission

PMC

Review

PMU

Primary

PIU/PMC

Secondary

DSC/PMC

Primary

PIU

Secondary

DSC/PMC

Primary

PMU

Secondary

PMC

Identification

DSC/PIU/ LD

Acquisition Proceedings

LD

12.0 FINANCE AND MAINTAINANCE OF S 12.1 Financial Management Control and maintenance of Project s

12.2 Preparation and submission of reimbursement claims for each city to PMU

12.3 Compilation, preparation and submission of reimbursement claims for the Project to the ADB

13.0 INTER DEPARTMENTAL AFFAIRS 13.1 Land acquisition

Primary 13.2 Identification of Power Connection, Railway crossing, and Road crossings. Pipe/Sewer interconnections with existing systems, permission for use of Forestland, etc. Secondary

DSC

13.3 Obtaining permissions from the other departments and organizing the works as required through them.

Primary

PIU

Secondary

DSC

Primary

DSC/PMC

Secondary

PIU/PMU

14.2 Preparation and implementation of time bound Management Action Plan (MAPs) to assist ULBs to improve their financial management and increase their resource generation, including computerization of activities. 14.3 Generating draft operational budgets (ULBs) for new works and facilities including normal operations and maintenance.

Primary

DSC/PMC PIU/PMU

PIU

14.0 OTHER RESPONSIBILITIES 14.1 Selection of appropriate commercially available software for routine activities

Secondary

Primary

PIU/PMU

Secondary

DSC/PMC

14.4 Assist (LDs/ULBs) in implementing cost recovery alternatives for recovering the cost of the capital improvements and meeting the recurring O & M expenditure.

Primary

DSC/PMC

Secondary

PIU/PMU

14.5 Review and assess training needs / requirements of the PMU, PIU & ULB.

Primary

DSC/PMC

Secondary

PIU/PMU

(PAGE 13)



14.6 Development of a comprehensive training plan to meet Primary identified needs. Secondary

DSC/PMC

14.7 Preparation of Training manuals and modules.

Primary

DSC/PMC

Secondary

PIU/PMU

Primary

DSC/PMC

Secondary

PIU/PMU

14.8 Providing on the job training for PMU, PIU and ULB staff

PIU/PMU

Note: The above procedures are prepared with a view of ensuring a smooth action in various activities, which generally have an overlapping responsibility. They are only a clarification on the responsibilities as prescribed in the respective contract documents. In case of variance, the contract documents will precede over the above stipulations. Wherever the responsibilities are shown to more then one agency, the order of precedence of responsibility is from left and that of authority is from right. Contractors are responsible for the execution of the works in conformance with the requirements of the contract documents.

2.1.1 General responsibilities Contractors are responsible for providing: •

all necessary plant, labor, equipment and construction materials to be used in the works;

•

all plant, equipment, materials and labor for temporary and auxiliary works;

•

all equipment and components to be installed or incorporated in the works;

•

transportation and storage facilities for all materials and equipment.

•

office and accommodation for staff and labor;

•

sanitation facilities at the site; and

•

all necessary staff and equipment for testing and quality control.

Contractors are responsible for executing and completing the works in accordance with the specified standards and specifications, within the contractual time allowed, and within the contract price for these works. On water supply and sewerage turnkey contracts, contractors are also responsible for preparing final design documents and obtaining their approval.

2.1.2 Quality assurance/quality control duties The contractor’s QA/QC duties are summarized in Table 2.2. Other duties shall be performed as stipulated in the contract documents or directed by the Engineer (PIU).

(PAGE 14)



Table 2.2 : List of Contractor’s QA/QC Duties Activity/Item

Designs for contracts

Contractor’s QA/QC Duties turnkey •

Prepare designs using appropriate QA/QC procedures

•

Submit designs and drawings to PIU for review and approval

•

Maintain design at site

•

Use only approved drawings for construction

Designs for item-rate • contracts •

Maintain design at site

Test laboratory and • equipment

Intimate PIU and DSC the details, date of completion with requisite manufacturers’ and calibration certificates

•

Maintain the equipment in good condition and calibrate as necessary

•

Enter receipts in material

•

Intimate PIU and DSC in writing

•

Prepare mix designs as required by contract and submit test results to PIU and DSC

•

Take test samples in presence of PIU and DSC when requested

•

Perform materials tests

•

Submit test reports to PIU and DSC with monthly reports

•

Maintain test log

•

Enter in material at site

•

Intimate PIU and DSC in writing the proposed date of removal from site and confirm after removal

Material consumption

•

Enter daily consumption of materials in material and indicate balance quantity

Construction equipment

•

Intimate PIU and DSC the details, date of mobilization along with requisite insurance certificate

•

Maintain equipment in good working condition

•

Intimate PIU and DSC in writing when construction is going to commence and what activities are proposed to be undertaken.

•

Intimate PIU and DSC in advance when critical works, such as concreting, embankment, paving, pipeline laying and ting, testing, etc., would be undertaken, along with the test certificates of the materials proposed to be used in these works. No critical activity shall start unless the material test certificates are verified and approved by the Engineer.

•

Provide necessary QA/QC

Material receipts

Materials testing

Rejected materials

Construction

Use only approved drawings for construction

(PAGE 15)



Activity/Item

Contractor’s QA/QC Duties

Daily work progress

•

Testing of works in • progress •

Perform tests as per contract requirements Submit test reports to PIU and DSC

•

Maintain test log

•

Intimate PIU and DSC in writing the proposed date of removal from site and confirm after removal, or (if so agreed by PIU and DSC)

•

Rectify defective work and invite PIU and DSC for reinspection.

from •

Enter change orders, site instructions, letters and minutes of meetings issued by the Engineer and Consultants in the Instruction Log

Rejected work items

Instructions Engineer

Maintain in daily log

Inspection of Engineer

•

Take instructions in Site Order Book.

•

Advise PIU and DSC of compliance

Progress scheduling • and control

Prepare and maintain project schedules and undertake work in accordance with approved schedule

Reporting

•

Records

Maintain the following records on site:

Prepare and submit Monthly Progress Reports

•

Material

•

Site Order Book

•

Hindrance

•

Daily Log

•

Design

•

Test Log

•

Instruction Log (to be maintained by DSC and Contractor both)

•

Equipment

•

Labor

•

Approved Construction Drawings

•

Test Reports

•

Site Laboratory Record

•

Permissions Issued by Departments

•

Correspondence Record

•

Copies of Monthly Progress Reports

•

Any other records as specified in the Contract and/or as instructed by the Engineer

(PAGE 16)


3


DESIGN CONTROL

This section outlines the final design preparation and review processes under the Project and presents basic design review criteria. As discussed in Section 2, the final design and drawing preparation responsibilities under the Project vary depending on the contracting procedure, as follows: •

For water supply, sewerage and solid waste management components under turnkey contracts, the final designs are prepared and submitted by the contractor, reviewed by the DSC & PIU and approved by the PIU. However the PIU may consult for special features with the PMC before approval. The PMU/PMC may at there own stipulate issues refereed to them. Preliminary designs and estimates for tendering purposes are prepared by DSC and reviewed by Technical committee

•

For all other item rate contracts (such as roads and bridges, water supply, sewerage storm water drainage, buildings, sites and services etc.) the designs are prepared by DSCs, reviewed by PIU, checked, reviewed and recommended by PMC, and approved by PMU.

Design control requirements are outlined below. The flow, handling and control of documents during design preparation and review are discussed in Section 10 of this Manual.

3.1

Design Preparation Process

Designs shall be prepared in accordance with the requirements of the Project, and applicable design standards and criteria, codes, specifications, and methodology. Final designs prepared by contractors on turnkey contracts shall be based on the preliminary designs prepared by DSC. For design calculations performed by computer, the design engineer shall design inputs and check outputs for reasonableness and compliance to requirements. Calculations prepared by hand shall be rechecked. The design engineer shall check the prepared designs and documents for completeness, correctness and legibility. Design documents and calculations shall be reviewed by a senior engineer to ensure that the design method is acceptable and in accordance with the contractual design criteria, codes and standards, that the inputs are correct and the outputs reasonable. Drawings will generally be prepared by computer aided design methods. As with design calculations, the designer shall check drawings for completeness, correctness, legibility and conformance to the design calculations, design standards, codes and specifications. A senior engineer shall then review drawings. A common discussion with senior engineer DSC & engineer in charge (PIU) are held .The comments of engineer in charge PIU being incorporated. Design documents, calculations and drawings shall be signed and dated by the draftsman (if applicable), the design engineer, and the reviewing senior engineer of DSC And Engineer In charge of PIU Should counter sign the same .

3.2

Design checking Review Process

The design checking reviewer ( PMC) shall examine the design documents, and if he has comments, prepare comment sheets and mark up a copy of the documents. If designs need to be reviewed by more than one person or agency, the primary reviewer shall consider the comments of other reviewers, discuss them as needed, and incorporate them into the marked up copy of the document.

(PAGE 17)



Each design document and drawing shall be reviewed for compliance with contract requirements and specifications, applicable standards, codes and criteria. If the reviewer questions the accuracy of calculations or dimensions established by the designer, he shall ask the designer to them but shall not change them himself. THE PMC will Provide a certificate for checking , reviewing & recommending the design for approval to PMU.

3.3

Design Review Checklist

A basic design review checklist is as follows: ο

Check document revision number and revision dates (if applicable).

ο

Check that the designer and reviewer have signed the document.

ο

the list of reference drawings and sources of special information and, as necessary, refer to the listed documents.

ο

Check the general notes for clarity and completeness.

ο

Review contract plans, specifications, addenda and all approved change orders, and check that the document complies with them.

ο

Check the accuracy and completeness of a representative set of calculations.

ο

Consider the aspect of constructability.

ο

Annotate the drawing, specification, addendum or other document as appropriate.

ο

Return the documents to the manager of the reviewing organization for return to the designer (PIU, DSC or contractor, as applicable).

Specific items to be checked depend on the type of facility being designed.

(PAGE 18)


4


CONSTRUCTION QUALITY CONTROL – GENERAL

This section provides an overview of construction quality control activities, including testing and site inspection. Materials control requirements are presented in detail in Section 5, while specific testing and inspection requirements for each category of works are presented in Sections 6 to 9 of this Manual.

4.1

Introduction

Construction quality control (CQC) is intended to provide a comprehensive, common and consistent framework for quality control across various contract packages. CQC comprises two main elements of quality control: •

Testing

•

Inspections

Testing control covers the type of tests to be carried out, frequency of testing and stage of testing. Inspection control covers the timing of inspections, what has to be inspected and the inspection procedures. CQC should be affected at five stages: •

Input Materials and Equipment Components

•

In-process Activities

•

Stage Completion

•

Interfacing (of special importance in water supply and sewerage contract packages)

•

Final Completion

The contractor is responsible to inform the DSC and PIU giving sufficient notice time so they can witness the test.

4.2

Testing

Various site tests on materials and works are required to be carried out by the contractor during construction. A well-equipped and properly operating site test laboratory is an important element of the quality assurance plan. A checklist showing typical testing equipment to be provided in the contractor’s site laboratory is presented as Table 4.1. The contractor shall set-up the site laboratory at the start of his project and inform the PIU and the DSC for conducting inspections. Laboratory equipment shall be properly calibrated, and calibration certificates should be kept at the laboratory for review by PIU and DSC, as necessary. Specialized tests at outside laboratories shall only be undertaken with the prior approval of the PIU. Tests should be performed in accordance with the contract documents, as described in Sections 5 through 8 of this Manual. The control of test reports shall be done as stipulated in Section 10 of this Manual. All test samples should be preserved, with proper identification numbers, test log reference, test date, and other applicable information. These samples must be stored on site by the contractor.

(PAGE 19)



Table 4.1 Checklist of Site Testing Laboratory Equipment Contract Package No: ______Name of Work:___________ Contractor Name:____________

Testing Equipment Balance (2 type) volume measuring apparatus & hand tools etc. Oven Sieves, sieve shaker and hydrometer Atterberg limit apparatus Procter/modified proctor (IS heavy) density equipment Sand replacement cylinder and core cutter Compression testing machine 100 MT and 5 MT capacity Cylinder and cube moulds Slump test Vicat apparatus Laboratory CBR equipment Dynamic cone penetration test equipment SPT equipment and hand auger Unconfined compression testing machine Direct shear equipment Consolidation test equipment Los Angles Abrasion test/ Impact Testing Machine Core drilling equipment Bitumen test equipment Measuring instruments Leak test equipment Marshal stability test equipment Metallic Digital Thermocouple Leveling instruments Any Others, Specify

Type of Test

Yes

No

(1)

(1)

General laboratory test

Drying and moisture content determination Grain size analysis and classification of soil and aggregates Plasticity of Soil Soil compaction test In-situ density test for field compaction control Compressive strength of cement, concrete, brick, etc. Concrete sampling Workability and control of water in concrete casting Setting time determination of cement Determination of strength of road pavement and layers Determination of strength of road pavement and layers Boring, sampling and soil strength test Determination of shear strength of cohesive soil Determination of angle of internal friction of soil Determination of settlement /compressibility of soil Los Angeles Abrasion test/ Impact Test In-situ sampling Ductility test and Penetration test Measurement of sizes Pipeline ting Road works. To be available at Hot Mix Plant site. Checking temperature of bitumen Tolerances of roads surfaces

Note: 1. Yes or No to be tick marked by PIU to indicate the equipment at the site laboratory)

(PAGE 20)



In addition to tests performed on site, the contractor is responsible for specialized tests which are performed at approved laboratories, and for factory inspections and tests performed by manufacturers or third parties during the manufacturing of various materials and equipment components, as stipulated in the contract documents.

4.3

Site Inspections

Site inspections shall be carried out to ensure that the materials and construction activities conform to the prescribed standards. Site inspections can be divided into day-to-day supervision and periodic quality inspection. The suggestions in respect of these two have been elaborated herein.

4.3.1 Day-to-day supervision The day-to-day site supervision of all construction activities shall be carried out by the DSC. This includes checking of lines, levels and layouts and on-site checks. Progress monitoring and expediting shall also be carried out by the DSC. The supervisory team of the DSC shall ensure that materials that have been rejected or for which a conformance report has not yet been issued are not used in works. Construction equipment is a major component of quality assurance system. The equipment requirements have been laid out in the Contract documents. It is necessary that the DSC check the adequacy of the equipment used by the contractor for construction as per the prescribed standards and specifications. The equipment used for construction shall be recorded in the daily logs.

4.3.2 Periodic quality inspections The ACM DSC & AE/EE PIU (engineer in charge) shall carry out periodic quality inspections during in-process, stage completion, interfacing and final completion, and during all critical activities as per the following examples: •

excavation

•

formation of embankments

•

placing of reinforcing steel

•

concrete batching and pouring (100% in presence of Engineer DSC and JE PIU)

•

hot mix operation

•

laying of pavement layers

•

laying and ting of pipes

•

installation of electrical and mechanical equipment

•

testing, trial runs and commissioning of electro-mechanical equipment and plants

The PIU and DSC shall also inspect the materials certified by manufacturers and materials and equipment components approved by third parties upon delivery to the site. The contractor shall give advance notice to the PIU and DSC when critical activities are proposed or major equipment items are to be delivered. On completion of one stage of the construction and before proceeding to the next stage (such as from sub-base to base in road works or from steel binding to concreting for RCC works) the DSC & engineer in charge of PIU shall inspect and certify the quality of the works completed before granting approval for the next stage of the works to start. The final inspection shall encom tests on completion and trial runs. The certification of quality will

(PAGE 21)



be based on the documents and the periodic site visits. The DSC representative and the PIU representative should witness not less than 30%and 10% of the test conducted respectively.

4.3.3 Squad checks The concept of Squad Checks has been adopted to have an external review of quality of works executed. The squad checks should be conducted tly by the PMU, PIU, PMC and DSC. A fixed timetable is not suggested for this. The tentative agenda for the squad checks is described as follows: •

physical inspection of the works under execution and inspection of quality of workmanship;

•

review of site documentation and contractor compliance;

•

sample verification of test reports and quality certificates;

•

review of issues, constraints and lacunae in quality system implementation;

•

preparing of action plans for improving the quality; and

•

performance appraisal of the contractors.

Formats for recording minutes of progress review meetings and for recording interim evaluations of contractor’s performance are included in Appendix C, as Format F-16 and F17 respectively.

4.4

Quality Certification and Acceptance

The DSCs shall be responsible to certify that the items included in the contractor’s Interim Payment Certificate satisfy the required quality of works and are acceptable with regard to the specifications and standards prescribed under the contract before the progress bill is ed for payment. PIU should signify acceptance of the DSC’s quality certification by counterg it. A format for this quality certification and acceptance is included in Appendix C, as Format F-18.

(PAGE 22)


5


CONTROL OF MATERIALS AND EQUIPMENT COMPONENTS

This section provides an overview of control requirements for materials and equipment components, including site testing, manufacturers’ certification and third party inspection.

5.1

General

Control and approval of construction materials and equipment components to be incorporated in the works shall be based on the following: •

Test reports for materials tested at site, such as cement, sand, water, aggregates and bitumen; The contractor will perform all tests. The designated DSC representative & PIU representative shall witness as per chapter 2. THEY shall sign the report in token of witnessing.

•

Manufacturer’s certificates and IS mark for manufactured items indicated in table 5.3 or as stipulated in the contract; and

•

Third party inspection for various items as per contract documents.

5.2

Materials Tested on Site

The materials to be tested on site include cement, water, aggregates for concrete, bricks and stones, soil for embankments, and aggregates and bituminous materials for road works. For aggregates and soil, the contractor shall obtain the approval of the borrow source or quarry from the PIU the DSC before extracting material. The list of materials to be tested on site is given in Table 5.1 below. Test procedures are presented in Table 5.2, under the referenced procedure numbers. Test report formats are included in Appendix A. The reports are to be maintained in a bound , where in 3 copies of report will be prepared, two copies to be submitted with monthly report to DSC & PIU and third copy to be retained by contractor. Table 5.1 Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

List of Materials Tested on Site Material Cement Sand Water for Construction Works (can be got tested in approved laboratory) Bricks Size Stone Coarse Aggregate for Concrete Work Soil/Earth/Sub-grade Material Granular Sub-base (GSB) Material Material for WBM / WMM Metal for BM/DBM/BC/Surface Dressing/MSS/Premix Carpet Binder for WBM Fine Aggregate for DBM/BC Lime Bitumen Borrow Material Steel (to be procured directly from manufacturer along with his test certificates) This shall also be got tested in local authorized test laboratory (by SE-PIU)

Test Procedure No. QC-M-01 QC-M-02 QC-M-03 QC-M-04 QC-M-05 QC-M-06 QC-M-07 QC-M-08 QC-M-09 QC-M-10 QC-M-11 QC-M-12 QC-M-13 QC-M-14 QC-M-15

(PAGE 23)



Table 5.2 Procedures for Testing Materials on Site CEMENT Sl. No.

QC-M-01

Type of Test

Test Report Format No.

Frequency of Test

Timing of Test/ Inspection

1

Normal consistency

TC-M-01-01

2

Fineness

TC-M-01-01

One for each source and when called for by the Engineer

3

Setting time – Initial / final

TC-M-01-01

4

Compressive strength -

TC-M-01-01

On receipt of material at site and before using as directed by the Engineer. Test certificate to be produced to the Engineer before use.

72 hrs, 168 hrs, 672 hrs. For sulphate resistant cement as per IS-12330 OPC 43/53 shall conform to IS 8112/ 12269 and both 56 and 90 days strength shall be tested.

SAND Sl. No. 1

Type of Test Sieve analysis

QC-M-02 Test Report Format No.

Frequency of Test

TC-M-02-01

One test for 15 m3 3

2

Fineness modulus

TC-M-02-01

One test for 15 m

3

Deleterious constituents

TC-M-02-01

One test for 15 m3

4

Bulking test

TC-M-02-01

One test per Source

WATER FOR CONSTRUCTION WORKS Sl. No.

Type of Test


1

Alkalinity and acidity as per IS-3025

TC-M-03-01

2

Solids

TC-M-03-01

Timing of Test/ Inspection On receipt at site and test certificate to be produced to the Engineer before use.

QC-M-03 Frequency of Test Once per source of supply and when called for by the Engineer

Timing of Test/ Inspection Before use of water from that source

(PAGE 24)



BRICKS Sl. No.

Type of Test


Frequency of Test One test per 50,000 bricks or part thereof

1

Compressive strength

TC-M-04-01

2

Physical properties

TC-M-04-01

3

Water absorption test

TC-M-04-01

SIZE STONE Sl. No.

Type of Test

Timing of Test/ Inspection On receipt at site


1

Water absorption test

TC-M-05-01

2

Dimension check

Lab format

3

Type of rock

Lab format

COARSE AGGREGATE FOR CONCRETE

Frequency of Test One test per source and when called for

QC-M-06

Type of Test


Frequency of Test

1

Aggregate Impact or Los Angeles Abrasion Value as per IS-2386 Part-IV

TC-M-06-01/1

One for each source of supply and when called for by the Engineer

2

Soundness as per IS2386 Part-V

TC-M-06-02

3

Alkali Aggregate Reactivity as per IS-2386 Part-IV

Lab Format

4

Flakiness Index

TC-M-06-03

5

Gradation by wet sieve analysis

TC-M-06-04

6

Water Absorption

TC-M-05-01

On receipt at site

As directed by the Engineer

Sl. No.

TC-M-06-01/2


Timing of Test/ Inspection On receipt of material at site

When required, the contractor shall furnish the mix design along with material properties at least 15 days in advance.

(PAGE 25)



SOIL/EARTH/SUB-GRADE MATERIAL Sl. No.

Type of Test

QC-M-07


Frequency of Test Two sets for 3000 m3 or part thereof

1.

Swelling index IS 2720 part XL

TC-M-09-01

2.

Liquid limits and plasticity index

TC-M-09-02

3.

Deleterious material IS 1498

4.

OMC & MDD Test

5.

Chemical properties

6.

Grain Size Distribution Graph (by wet sieve analysis)

7.

Void ratio gradation

8.

Soaked CBR test (optional)

Type of Test

On receipt at site

Lab format TC-M-09-03 Lab format TC-M-09-04

Lab format TC-M-07-01

Two sets for 3000 m2 or part thereof and as directed by the Engineer

GRANULAR SUB-BASE MATERIAL Sl. No.



1

California Bearing Ratio Test

TC-M-07-01

2

Material combinations

3

Moisture content as per IS-2270

TC-M-07-02

4

Fineness value BS 812 Part III

Lab format

5

Soundness of material

TC-M-06-02

6

Air voids content

7


TC-M-06-04

8

Atterberg limits

TC-M-09-02

9

Deleterious constituents

10

OMC and MDD

QC-M-08 Frequency of Test


As required

On receipt at site

1 test per 250 m3 or part thereof

Prior to compaction

As required

On receipt at site

Daily log

Lab format 1 test per 200 m3 or part thereof

Lab format TC-M-09-03

The contractor shall furnish the GSB design mix along with material properties and test results at least 15 days before laying GSB at site.

(PAGE 26)



MATERIAL FOR WBM / WMM Sl. No.

Type of Test

1

Aggregate Impact Value


QC-M-09 Frequency of Test

TC-M-06-01/1 One test for 200 m3 3

2

Grading by wet sieve analysis

TC-M-06-04

One test for 100 m

3

Flakiness Index and Elongation Index

TC-M-06-03

One test for 200 m3 of aggregate

4*

Atterberg limits of binding material

TC-M-09-02

One test for 25m3 of binding material

Timing of Test/ Inspection On receipt at site

*(Only for WBM) 5

Atterberg limits of portion of aggregate ing 425 micron sieve.

TC-M-09-02

One test for 100 m3 of aggregate

6

Water Absorption Test

TC-M-05-01

Initially one set of 3 representative specimen for each source of supply and subsequently, when warranted by changes in the quality of aggregate

7

Soundness Test

TC-M-06-02


8*

Density of compacted layer of WMM

On receipt at site and when absorption value is more 2%

One test for 500 m3

*(Only for WMM)

METAL FOR BM / DBM / BC / SURFACE DRESSING / MSS / PRE-MIX CARPET Sl. No.

Type of Test


1

Aggregate Impact Value

TC-M-06-01/1

2

Flakiness Index and Elongation Index of aggregates

TC-M-06-03

3

Water absorption of aggregates

TC-M-06-06

QC-M-10 Frequency of Test One test for 50 m3 of aggregate or part thereof

Timing of Test/ Inspection On receipt at site and before using in the hot mixing

Initially one set of 3 representative

(PAGE 27)



METAL FOR BM / DBM / BC / SURFACE DRESSING / MSS / PRE-MIX CARPET Sl. No.

Type of Test

QC-M-10


Frequency of Test

4

Stripping value

TC-M-11-01

specimen for each source of supply and subsequently, when warranted by changes in the quality of aggregate

5


TC-M-06-04

As directed by the Engineer for individual component and for combined coarse, fine aggregate and filler.

6

Soundness Test

TC-M-06-02



On receipt at site and when absorption value is more than 2%

For DBM and BC, the contractor shall furnish the material properties and proposed job mix formula at least 20 days in advance.

BINDER FOR WBM Sl. No. 1

QC-M-11

Type of Test


Frequency of Test

Atterberg Limit Test

TC-M-09-02

One test for 100 m3 of binding material

FINE AGGREGATE FOR DBM/BC Sl. No.

Type of Test


Frequency of Test

ing 2.36 mm sieve and retained on 75 micron sieve

Daily log

As directed by the Engineer

2

Deleterious matter

Daily log

Visual observation of lot before use

Sl. No.

Type of Test

On receipt at site

QC-M-12

1

LIME


Timing of Test/ Inspection Before use


Frequency of Test 3 final test samples for a lot size up to 100 tons as per Table 3 in IS 712-1984.

1

Chemical properties as per IS: 6932, 1514

Lab format

2

Physical properties as per IS: 6932

Lab format

Timing of Test/ Inspection On receipt at site.

(PAGE 28)



BITUMEN Sl. No.

Type of Test


Frequency of Test


Two samples per test subject to all or some tests as directed by the Engineer

On receipt of material at site before unloading from the truck

1

Grade of bitumen as directed/defined (Penetration Test)

TC-M-10-01

2

Ductility Test

TC-M-10-02

3

Flash and Fire Point Test

Lab format

4

Viscosity Test

Lab format

5

Softening Test

Lab format

BORROW MATERIAL

QC-M-15

(Soil to be used in Embankment / Subgrade / GSB) Sl.

Type of Test

No.


Frequency of Test


No format

25 m c/c or closer depending upon soil strata variation

Before material is extracted for use in construction.

2 sets of observation per 3000 m3 of soil and in each 6 observations required.

Before material is extracted for use in construction.

1

Digging of borrow area for sampling

2

Sand Content

TC-M-15-01

3

Wet Sieve Analysis

4

Plasticity Index

5

Modified Proctor Density

6

Soaked CBR Test

(use relevant test report formats and summarize results in TCM-15-01)

7

OMC

8

MDD

Borrow material source must be approved before extracting material.

5.3

Materials And Equipment Certified By Manufacturer

Acceptance of certain manufactured materials and equipment components, as stipulated in the contract, shall be based on test certificate(s) from the manufacturer conforming to IS and on visual inspection. These items shall bear the IS mark. PIU and DSC shall review the manufacturers’ certificates for conformance to contract requirements before these items are delivered to the site. Upon their delivery and before their installation or otherwise incorporation in the works PIU and DSC shall inspect the condition of these items. Inspection criteria shall be decided tly by PIU and DSC. They may decide to have the material additionally tested in Laboratory. The cost of such tests will be borne by the contractor. Materials and equipment subject to manufacturer’s certification are listed in Table 5.3.

(PAGE 29)



Table 5.3 List of Materials and Equipment Certified by Manufacturer •

Steel/Reinforcing Steel

•

Paint, Primers and Protective Coatings

•

Glazing

•

Water Proofing Compound

•

GI, CI and PVC Pipes for general civil works

•

Glazed Stoneware Pipes (GSW) for general civil works

•

Gratings & Plates

•

Manhole Covers

•

Sanitary Fittings

•

Metal Works such as windows, barbed wire, MS ladder, footrest, rolling shutters, etc.

•

t Filler Material

•

Pre-fabricated Water Tanks

•

Traffic Signs

•

Flow Measuring Devices – General

•

Foot Rests

•

Electrical Conduits

•

Electrical Wires/Cables

•

Switches & Sockets

•

Distribution Boards

•

Lights, Fans and Fixtures

•

Earthing Material

•

Insulators

•

GOS

•

DOLO

•

Lightening Arrestor

•

Batteries

•

Cable Termination Kit

•

Fire Fighting Equipment

•

Reduction Gearboxes

•

Level Indicator & Controllers

•

Laboratory Equipment

•

Electrical Poles

•

All other items as specified in the contract documents

(PAGE 30)


5.4


Materials And Equipment Inspected By Third Party

Materials and equipment to be inspected by a third party vary from package to package, as stipulated in the contract documents. Third party inspection would normally take place at the factory during or upon completion of manufacture. Before site delivery, PIU and DSC shall review the third party inspection certificates for conformance to requirements. Upon delivery and before installation or incorporation in the works, PIU and DSC shall inspect the physical condition of these items and, if necessary, test them on site. Inspection criteria should be stipulated in the contract document. A list of materials and equipment suggested for inspection by third party is given in Table 5.4. Table 5.4 List of Materials and Equipment Inspected by Third Party •

Flow Measuring Devices – Special

•

Cranes & Lifting Tackles

•

Electrical Cables – Special

•

Butterfly Valves

•

Sluice Valves

•

Reflux Valves

•

Air Valves

•

Control Valves

•

Vertical Turbine Pumps/Other Pumps

•

Vertical Motors/Other Motors

•

Gauges

•

Electrical Starters

•

Power Transformers

•

Voltage Transformers

•

Current Transformers

•

Bus Ducts

•

Switch Boards (HV/MV/LV)

•

Battery Chargers

•

DC Distribution

•

Steel Pipes – Lined & Coated

•

Pre-stressed Concrete (PSC) Pipes

•

NP Pipes for Sewers

•

GSW pipes for sewers

•

DI, CI ad PVC pipes for PHED works

•

All specials and fittings for Water Supply and Waste Water Systems

(PAGE 31)



•

In-situ Welding of Pipes

•

In-situ Lining of Pipes

•

Aerators for STP

•

Clariflocculator

•

Flash Mixer for WTP

•

Motor Control Centre

•

Indication-cum-Enunciation

•

Capacitors

•

Sluice Gates

•

Cable Trays

•

All other items as specified in the contract documents

(PAGE 32)


6


CONTROL OF GENERAL CIVIL AND STRUCTURAL WORKS

This section of the QA/QC Manual covers the testing of works and the inspection of workmanship for general civil and structural works. The key elements to be inspected in these works are concreting, stone masonry, and brickwork and finishes. The requirements for testing and control of materials for these works are outlined in Section 5.

6.1

Construction Sequence and Control Flow Charts

Flow charts indicating the construction sequence and control points for cement concrete and mortar works are shown in Figure 6.1 and 6.2 respectively.

6.2

Testing of Works

The works to be tested on site include excavation, cement concreting, and stone and brick masonry. All the materials proposed to be used in these works must have been tested by the contractor and approved by the DSC well in advance of these works. The contractor shall submit the concrete pouring report to the PIU and DSC as and when concreting is done, and shall obtain the approval of the DSC when a particular stage is completed and before proceeding to the next stage. Tests for general civil and structural works are listed in Table 6.1. Test procedures are presented in Table 6.2, under the referenced test numbers. Required materials tests are also indicated (materials testing procedures are presented in Section 5). Test report formats are included in Appendix A. The contractor shall conduct tests as stipulated. The Representative of DSC and PIU will witness not less than 30% and 10 % of all the test conducted respectively.. This minimum percentage is not applicable where a higher % of this inspection is stipulated elsewhere.

6.3

Inspection Checklists

Inspection checklists for concreting, stone masonry, and brick masonry work and finishes, and building services and finishes are presented in Appendix B.

(PAGE 33)



(PAGE 34)



(PAGE 35)



Table 6.1 List of Tests for General Civil and Structural Works Sl. No.

Process

Material Name

1

Embankment Formation

2

Excavation/Backfilling

3

Concreting

4

5

Size Stone Masonry

Brick Masonry

Soil/Earth

Test Ref. No.

Format No. QC-M-07

QC-G-01 QC-G-02

Steel

MC (1)

Cement

QC-M-01

Coarse Aggregates

QC-M-06

Sand

QC-M-02

Water

QC-M-03

Size stone

QC-M-05

Cement

QC-M-01

Sand

QC-M-02

Water

QC-M-03

Bricks

QC-M-04

Cement

QC-M-01

Sand

QC-M-02

Water

QC-M-03

QC-G-03

QC-G-04

QC-G-04

Note: 1. MC = manufacturer certified. Table 6.2 Procedures for Testing General Civil and Structural Works Embankment Formation Sl. No.

Type of Test

QC-G-01


Frequency of Test

1


TC-M-09-03

One test for each 250 m3 of soil

2

Field density test as per IS-2720

TC-M-09-03

5-10 density tests for each 1000 m2 compacted area, or as directed by Engineer

3

Compaction

Daily log

As per required number of es

Timing of Test/ Inspection In-process

While compacting

(PAGE 36)



Excavation/Backfilling Sl. No.

Type of Test

QC-G-02


1

Layout, slopes of excavation, benching and over-burden

Daily log

2

Sub-soil water, shoring and strutting

Daily log

3

Bottom levels and compaction

Daily log

4

Soil classification

Daily log

5

Backfilling and compaction

Daily log

Frequency of Test As directed by the Engineer

QC-G-03

Sl. No.

Type of Test


1

Compressive strength as per IS-516

TC-G-01-01

Slump test per IS-1199

3

Inspection of steel reinforcement placement and bending, and formwork

4

Concrete Pour Report

After excavation

After backfilling

Concreting

2


TC-G-01-02

Daily log

TC-G-01-03

Frequency of Test •

One test for 1-5 m3 of concrete

•

Two tests for 6-15 m3 of concrete

•

Three tests for 1630 m3 of concrete

•

Four tests for 3150 m3 + one set every 50 m3 of additional concrete work.

Timing of Test/ Inspection Test samples to be taken while pouring. Testing to be done as specified in contract.

Random checks throughout concreting as directed by the Engineer

Before pouring concrete



When pouring is done

Immediately after pouring

(PAGE 37)



Mortar

QC-G-04

Sl. No.

Type of Test


Frequency of Test


1


TC-G-01-01

2

Consistency as per IS2250

TC-G-02-01

One sample for every 2 m3 of mortar subject to a minimum of three samples for a day’s work

Test samples to be taken while before mortaring. Testing to be done as specified in contract.

(PAGE 38)


7


CONTROL OF ROAD WORKS

This section of the QA/QC Manual covers the testing of works and the inspection of workmanship for road works, including earthworks, placement of sub-base and WBM layers, application of prime and tack coats, and placement of bituminous layers. The requirements for testing and control of materials for road works are outlined in Section 5.

7.1


Flow charts indicating the construction sequence and control points for road works are shown in Figures 7.1 to 7.9.

7.2

Testing of Works

The works to be tested on site include earthworks, placement of granular sub-base and WBM layers, application of prime and tack coats, and placement of bituminous layers. All the materials proposed to be used in these works must have been tested by the contractor and approved by the DSC well in advance of the works. The contractor shall obtain the approval of the DSC when a particular stage is completed and before proceeding to the next stage. Surface regularity and alignments shall be checked by leveling instrument. Hot mix designs shall be submitted by the contractor to PIU and DSC for review and approval well before the planned start of hot mix operations. The hot mix plant shall be inspected by PIU and DSC and approved by PIU before commencing operations. Temperature tests on bitumen shall be carried out at the hot mix plant before delivery to the site, and immediately before placing and after compaction. Temperature tests shall be carried out by using metal digital thermocouple based temperature measuring device. The Contractor shall provide such devices as part of his site laboratory, and in sufficient quantity so that all required testing can be carried out as-and-when required. The contractor shall take the temperature readings in the presence of the DSC, and shall submit his test reports on a daily basis. Tests for road works are listed in Table 7.1. Test procedures are presented in Table 7.2, under the referenced test numbers. Required materials tests are also indicated (materials testing procedures are presented in Section 5). Test report formats are included in Appendix A.

7.3


An inspection checklist for road works is presented in Appendix B.

(PAGE 39)



(PAGE 40)



(PAGE 41)



(PAGE 42)



(PAGE 43)



(PAGE 44)



(PAGE 45)



(PAGE 46)



(PAGE 47)



(PAGE 48)



Table 7.1 List of Tests for Road Works Sl. No. 1.

Process

Material Name

Embankment Formation

Soil/Earth

Test Ref. No.

Format No. QC-M-07

QC-R-01

QC-M-15 2.

Excavation

QC-R-02

3.

Granular Sub-base Laying

Granular Subbase

QC-M-08

QC-R-03

4.

WBM Laying

WBM

QC-M-09

QC-R-04

Binder

QC-M-11

5.

Prime Coat Application

Bitumen

QC-M-14

QC-R-05

6.

Tack Coat Application

Bitumen

QC-M-14

QC-R-05

7.

Surface Dressing

Bitumen

QC-M-14

QC-R-06

Metal

QC-M-10

Bituminous Macadam Laying

Bitumen

QC-M-14

Metal

QC-M-10

DBM Laying

Bitumen

QC-M-14

Metal

QC-M-10

Fine Aggregates

QC-M-12

Filler (Lime)

QC-M-13

Bitumen

QC-M-14

Metal

QC-M-10

Fine Aggregates

QC-M-12

Bitumen

QC-M-14

Metal

QC-M-10

Fine Aggregates

QC-M-12

8.

9.

10.

11.

12.

Mix Seal Surfacing

Bituminous Concrete Laying

On Completion of Laying of BM / DBM / BC

Filler (Lime) QC-M-13 Stage completion test

QC-R-07

QC-R-08

QC-R-06

QC-R-08

QC-R-09

(PAGE 49)



Table 7.2 Procedures for Testing Road Works Embankment Formation Sl. No.

Type of Test

QC-R-01


Frequency of Test

1


TC-M-09-03


2


TC-M-09-03

•

For earthwork in embankment/cutti ng 5-10 density tests for each 1000 m2 compacted area

•

For earthwork in sub grade/GSB and shoulders, 10 density tests for 500 m2 compacted area

3

Rolling operation

Daily log

Excavation Sl. No.

Type of Test

As per required number of es


While rolling

QC-R-02 Test Report Format No.

1

Layout, slopes of excavation, benching and over-burden

Daily log

2

Sub-soil water, shoring and strutting

Daily log

3

Bottom levels and compaction

Daily log

4

Soil classification

Daily log


Timing of Test/ Inspection After excavation

(PAGE 50)



Granular Sub-Base Laying Sl. No.

Type of Test

QC-R-03


Frequency of Test

1


TC-M-09-03

One test for 500m2 of compacted soil (3 observations per test)

2


TC-M-09-03

10 observations selected randomly for every 500m2 of compacted area

3

Rolling operation

Daily log

Required No. of es

WBM Laying Sl. No. 1

Type of Test Field Density Test by sand replacement method

Type of Test

In-process

While rolling

QC-R-04 Test Report Format No. TC-R-06-01


Prime Coat/Tack Coat Application Sl. No.



1

Temperature Test

Daily log

2

Rate of spreading

TC-R-02-01


QC-R-05 Frequency of Test At regular close intervals


Three tests for every 50 m length

Surface Dressing/Mix Seal Surfacing/

QC-R-06

Pre-mix Carpet Sl. No. 1

Type of Test Rate of spread of mix material


Frequency of Test

TC-R-02-01

One test for every 500 m3 of mix with 6 observations

Bituminous Macadam Laying Sl. No.

Type of Test

1

Temperature Test

2

Rate of spread of mix material

Test Report Format No. Daily log TC-R-02-01


QC-R-07 Frequency of Test At regular close intervals


2-3 observations at every 10 m interval during paving

(PAGE 51)



DBM/BC Laying Sl. No.

Type of Test

QC-R-08 Test Report Format No.

1

Temperature Test

Daily log

2

Rate of spread of mix material

TC-R-02-01

3

Stability of Mix/Marshal Stability Test

TC-R-05-01

Frequency of Test


At regular close intervals

In-process

3 samples for each 400 tons of mix produced subject to a minimum of 2 tests per plant per day.

While hot mixing

On Completion of BM / DBM / BC Layers

QC-R-09

Stage Completion Test Sl. No.

Type of Test


Frequency of Test

1

Core test for compacted layer (bitumen content, density and voids)

TC-R-07-01

One test for 250 m2 of compacted area

2

Surface regularity and control of alignment

TC-R-07-02

One test for every 300 m of road length

7.4

Timing of Test/ Inspection On completion of stage and before proceeding to next stage

Guidelines for Pavement Layers

Guidelines for gradation and placement of WBM layer are given in Table 7.3 and 7.4, respectively; guidelines for application of prime and tack coats are given in Table 7.5; and requirements of bituminous mixes are given in Table 7.6. (These guidelines are provided for easy reference. The standards and specifications stipulated in the contract shall be adhered to.) Table 7.3 Gradation for WBM Layers Grade-II

Grade-III

Screening Material

(Size: 63 mm to 45 mm)

(Size: 53 mm to 22.4 mm)

(Size: 11.2 mm)

IS Sieve Designation (mm)

% by weight ing


% by weight ing


% by weight ing

90

100

63

100

11.2

100

63

90-100

53

95-100

5.6

90-100

53

25-75

45

65-90

0.18

15-35

45

0-15

22.4

0-10

22.4

0-5

11.2

0-5

(PAGE 52)



Table 7.4 Guidelines for Placement of WBM Layers Quantity Required for 10 Sq. m Area (Compacted thickness 75mm) Grading

Size (mm)

Loose Quantity (m3)

II

63-45

0.91-1.07

III

53-22.4

0.91-1.07

Screening Material for II

11.2

0.20-0.22

Screening Material for III

11.2

0.18-0.21

---

0.06-0.09

Binding Material (II/III)

Table 7.5 Guidelines for Prime/Tack Coat Application Particulars

Standard Specified Rate (kg/m2)

Granular surface treated with primer

0.25-0.30

Granular base not primed

0.35-0.40

Normal bituminous surfaces

0.20-0.25

Table 7.6 Requirements of Bituminous Mixes Minimum stability (kN at 60o C)

9.0

Minimum flow (mm)

2

Maximum flow (mm)

4

Compaction level (Number of blows)

Percent air voids Percent voids in mineral aggregate (VMA) Percent voids filled with bitumen (VFB)

75 blows on each of the two faces of the specimen 3-6 See table 7.6(a) 65-75

(PAGE 53)



Table 7.6 (a) Minimum percent Voids in Mineral Aggregate (VMA) Nominal Maximum Particle size (mm)

Notes: 1. 2.

7.5

Minimum VMA, percent Related to Design Air Voids, Per cent2 3.0

4.0

5.0

9.5

14.0

15.0

16.0

12.5

13.0

14.0

15.0

19.0

12.0

13.0

14.0

25.0

11.0

12.0

13.0

37.5

10.0

11.0

12.0

The niominal maximum particle size is one size larger than the first sieve to retain more than 10 per cent. Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values between those listed.

Tolerances

Requirements for surface regularity and tolerances are given below. (These requirements are for easy reference; the standard and special technical specifications as per the contract must be referred.)

7.5.1 Horizontal alignment tolerances The horizontal alignment with respect to the centerline of the carriageway shall have a tolerance of +10 mm at the edges of roadway and of +25 mm lower layers.

7.5.2 Surface levels tolerances Surface level tolerances are shown in Table 7.7. Table 7.7 : Surface Level Tolerances Type of Surface

Tolerance in Level Compared with Longitudinal and Cross Profile

Sub-grade

+ 20 mm/- 25 mm

Sub-base

+10 mm/- 20 mm

Base Course (a) Machine laid

+10 mm

(b) Manually laid

+15 mm

Wearing Course (a) Machine laid

+6 mm

(b) Manually laid

+10 mm

Cement concrete pavement

+5 mm -6 mm*

* This may not exceed -8 mm at 0-30 cm from the edges.

(PAGE 54)



7.5.3 Surface regularity of pavement courses The maximum allowable difference between the road surface and a straight line parallel with or at right angles to the centerline of the road at points shall be: •

For bituminous surface:

•

For GSB/base courses : 8 mm

3 mm

The maximum permitted number of surface irregularities measured under a 3 m long straight edge at the middle of each traffic lane along a line parallel to the center line of the road shall be as shown in Table 7.8. Table 7.8 Maximum Number of Surface Irregularities Maximum Number of Surface Irregularities on Bituminous Road and Shoulders

Irregularity

4 mm

7 mm

Length (m)

300

75

300

75

National/State Highways

20

9

2

1

Town Roads

40

18

4

2

(PAGE 55)



(PAGE 56)


8


CONTROL OF PIPELINE WORKS

This section of the QA/QC Manual covers the testing of works and the inspection of workmanship for pipeline works (i.e. water and sewer lines) and liquid retaining structures. The requirements for testing and control of input materials are outlined in Section 5.

8.1


Flow charts indicating the construction sequence and control points for materials used in pipeline work and for pipeline works are shown in Figure 8.1 and 8.2 respectively.

8.2

Testing of Works

The works to be tested on site include bedding for pipelines, pipeline laying and ting, and hydrostatic, leakage and water tightness tests after completion. All the materials proposed to be used in these works must have been tested by the Contractor and approved by the DSC well in advance of commencing works. The contractor shall obtain the approval of the DSC when a particular stage is completed and before proceeding to the next stage. Tests for pipeline works and liquid retaining structures are listed in Table 8.1. Test procedures are presented in Table 8.2, under the referenced test numbers. For excavation, back-filling and re-paving works refer to Sections 6 and 7 of this Manual. Required materials tests are also indicated (materials testing procedures are presented in Section 5). Test report formats are included in Appendix A.

8.3


An inspection checklist for pipeline works is included in Appendix B.

(PAGE 57)



(PAGE 58)



(PAGE 59)



(PAGE 60)



Table 8.1 List of Tests for Pipeline Works and Liquid Retaining Structures Sl. No.

Activity

Material Name

1

Test Ref. No.

Format No.

Bedding for Pipeline

1.1

Earth Bedding

Earth/Soil

QC-M-07

1.2

Gravel Bedding

Gravel

QC-M-08

1.3

Concrete Bedding

Cement

QC-M-01

Sand

QC-M-02

Water

QC-M-03

Coarse Aggregate

QC-M-06

Steel 2 2.1

2.2 2.3

QC-P-01 QC-P-02

MC (1)

Pipeline Laying and ting GSW Pipe

RCC and CI Pipes Coated and Lined Steel/PSC Pipes

Cement

QC-M-01

Sand

QC-M-02

Water

QC-M-03

Pipes

MC (1)

Pipes

TPI/MC (1)

Gaskets

TPI/MC (1)

Coated and lined steel/

QC-P-03

QC-P-02

TPI (1)

PSC pipes 3

Manhole/Valve Chamber Construction

Cement

QC-M-01

QC-P-02

Sand

QC-M-02

QC-P-03

Water

QC-M-03

Bricks

QC-M-04

Coarse Aggregate

QC-M-06

Cover

TPI (1)

Frame/Vent shaft etc.

MC (1)

Steel

MC (1)

4

Completion of Pipeline Laying and ting

Stage Completion Test

QC-P-04

5

Completion of Manhole/ Valve Chamber Construction


QC-P-05

6

Completion of Liquid Retaining Structures (Wet Wells, Storage Reservoirs, Pretreatment Units, RCC Open Channels, etc.)


QC-P-06

Note: 1.

MC = manufacturer certified; TPI = third party inspection.

(PAGE 61)



Table 8.2 Procedures for Testing Pipeline Works and Liquid Retaining Structures Earth Bedding Sl. No.

Type of Test

QC-P-01 Test Report Format No.

Frequency of Test

1


TC-M-09-03


2


TC-M-09-03

One test for each 100 m2 of compacted area

Concreting


QC-P-02

Sl. No.

Type of Test


1


TC-G-01-01

Frequency of Test • • • •

2

Slump test per IS-1199

TC-G-01-02

3

Steel reinforcement placement and bending

Daily log

4

Concrete Pour Report

TC-G-01-03

Mortar


One test for 1-5 m3 Test samples to be taken while of concrete pouring. Tests Two tests for 6-15 to be done as 3 m of concrete specified in the Three tests for 16- contract. 30 m3 of concrete Four tests for 3150 m3 of concrete + one set every 50 m3 of additional concrete work.

Random checks throughout concreting period as directed by the Engineer




When pouring is done

Immediately after pouring

QC-P-03

Sl. No.

Type of Test


Frequency of Test


1


TC-G-01-01

2

Consistency as per IS2250

TC-G-01-02

One sample for every 2 m3 of mortar subject to a minimum of three samples for a day’s work

Test samples to be taken while placing. Tests to be done as specified in the contract.

(PAGE 62)



Completion of Pipeline Laying and ting Sl. No.

Type of Test


QC-P-04 Frequency of Test


1

Hydrostatic test for NP pipes

TC-P-04-01

One test for defined stretch

On completion of stage

2

Hydrostatic test for pressure pipes

TC-P-04-02

One test for defined stretch

On completion of stage

Completion of Manhole/Valve Chamber Sl. No. 1

Type of Test Leakage Test

Test Report Format No. TC-P-05-01

Completion of Liquid Retaining Structures Sl. No.

Type of Test

QC-P-05 Frequency of Test 100% inspection

Timing of Test/ Inspection On completion of stage

QC-P-06


Frequency of Test

1

Water tightness for underground structures

TC-P-06-01

One test per structure

2

Water tightness for elevated structures

TC-P-06-02

One test per structure

Timing of Test/ Inspection On completion of stage

(PAGE 63)



(PAGE 64)


9


CONTROL OF ELECTROMECHANICAL WORKS

This section of the QA/QC Manual gives an overview of the quality control requirements for electromechanical works, such as water treatment and supply systems, sewage treatment plants, compost plants, pumping systems, and power supply and distribution systems. The requirements for testing and control of input materials and components, including manufacturers’ certification and third party inspections, are outlined in Section 5. Materials and components to be incorporated into electromechanical works shall be inspected by PIU and DSC as soon as they are delivered, to ensure that they meet the specifications and design requirements, are in agreement with shipping documentation, and are accompanied by manufacturer’s certifications or third party inspection certificates, as applicable. Accepted materials and equipment shall be properly stored by the contractor until needed. If manufacturer’s installation instructions conflict with design or contract requirements, the PMU, PIU and PMC shall be notified immediately. Installation shall proceed only after the conflict has been resolved. A series of inspections and tests during installation and completion of electromechanical works shall be performed by the contractor or the equipment manufacturer and witnessed by PIU and DSC, as follows: •

Preparatory Inspections: Prior to installation, the civil and structural works where electromechanical equipment is to be installed shall be inspected to ensure conformance with designs and equipment installation requirements.

•

Installation Inspections and Tests: A system of inspections and tests, as specified in the contract or recommended by the equipment manufacturer, shall be employed throughout movement to position and installation of equipment and systems. Inspections shall be performed by DSC at critical points during installation. Surveillance shall be provided by PIU/DSC throughout the progress of work to ensure that installation is performed in accordance with the contract requirements, approved drawings, acceptable workmanship standards and configuration control requirements. All field modifications and retrofit work shall be performed under the surveillance of the PIU and DSC installation inspector.

•

Installation Verification Inspections: Prior to all mechanical and electrical testing, verification inspections shall be performed to ensure that equipment has been satisfactorily installed.

•

System Tests: These tests shall be conducted as appropriate to demonstrate that the installed systems are free from damage due to shipment and installation, and that equipment performs in accordance with specifications.

•

Integrated Tests: After completion of system tests, integrated tests shall be performed to demonstrate that the system performs satisfactorily when connected to its interfacing systems or sub-systems. These tests will be followed up by commissioning tests.

•

Commissioning Tests: These consist of a series of tests performed under service operating procedures to demonstrate compatibility of the physical plant with operating procedures.

•

Final Inspections: Final inspections shall be performed to ensure that the completed work is in accordance with the contract and that all previously identified discrepancies have been resolved satisfactorily.

(PAGE 65)



(PAGE 66)


10


DOCUMENT CONTROL

Document control is intended to provide a consistent framework for transmittal, receipt, recording, processing, filing and retrieval of documents, and to ensure commonality in formats. The most important documents for QA/QC are final design documents, test reports and instructions. A flow chart for control of these documents is shown in Figure 10.1. Document control procedures, including guidelines for correspondence control, are outlined below.

10.1 Design Document Control As discussed earlier (See Section 3), final design documents (drawings, calculations, estimates, etc.) are generated at three separate levels, depending on the contracting procedure and type of work. These factors have been considered in suggesting the design document control system.

10.1.1 Turnkey contracts The flow of final design documents prepared by the contractor in turnkey contracts shall be as follows: 1. The contractor shall submit three copies of design documents to PIU for review, using the Request for Design Approval (RDA) Format F-1 of Appendix C. 2. The PIU shall send one copy of the documents to DSC for review and comments, using the Request for Internal Design check Review and recommendation (RIDCRR) Format F-2 of Appendix C. 3. After review, the DSC shall return the documents with its comments, using the Internal Design check Review and recommendation Note (RIDCRR) Format F-3 of Appendix C. 4. Taking into the comments of DSC, the PIU shall get it reviewed & checked from PMC with its recommendation for approvals & not approval using (RIDCRR) format F-2 and accordingly return the design documents to the contractor, using the Design Transmittal Note (DTN) Format F-4 of Appendix C. Design documents shall be marked (or stamped) ‘Approved’, ‘Approved as Noted’ or ‘Not Approved’. 5. For design documents marked ‘Not Approved’, steps 1 to 4 above shall be repeated. For documents noted ‘Approved’ or ‘Approved as Noted’, the contractor shall submit originals to PIU for affixing ‘Approved’ signatures (using a format similar to F-1.). 6. The PIU shall have the design documents signed ‘Approved’ and return them to the contractor (using a format similar to F-4). 7. The design document details are to be recorded in the contractor’s Design/Drawing , using the Format F-5 of Appendix C. (Similar s shall also be kept by PIU and DSCs.)

(PAGE 67)



(PAGE 68)



10.1.2 Item rate contracts (Wending Drawings) The design documents are prepared by the DSC. The flow of documents is summarized below. 1. Copies of design documents prepared by DSC shall be forwarded to PIU and PMC for review, using the Request for Internal Design Approval (RIDA) Format F-2 of Appendix C with copy to PMU for information. 2. After review, PMC shall forward to PIU the documents with its comments, using the Internal Design Review Note (IDRN) Format F-3 of Appendix C. 3. Taking into the comments of PMU/PIU/PMC for modification if any , the PIU shall return the design documents to DSC, using the Internal Design Transmittal Note (IDTN) format F-9 of Appendix C. Design documents shall be marked (or stamped) Recommended for approval as ‘ Noted’ or ‘Not Approved’. 4. For design documents marked Recommended for approval as noted ‘Not Approved’, steps 1 to 3 above shall be repeated. For documents noted ‘Approved’, the DSC shall submit originals to PIU/PMU for affixing ‘Approved’ signatures (using a format similar to F-8.). 5. After the design documents have been signed ‘Approved’ for construction, they shall be transmitted to the contractor by PIU, using the Approved Design Release Note (ADRN) Format F-6 of Appendix C. 6. The document details are to be recorded in the contractor’s Design/Drawing , using Format F-7 of Appendix C. (Similar s shall also be kept by DSCs.) 7. The detailed construction drawings prepared by contractor/DSC may be approved by PIU. PIU may refer if they feel it necessary to PMC/PMU for review.

10.2 Test Report Controls All the tests and field checks are to be carried out as per the applicable quality control requirements. The tests are carried out by the contractor who will designate (Engineer) a laboratory-in-charge authorized to sign test reports for him. The witnessing officer will sign the reports and put his name and designation. The flow of test report documentation shall generally be as follows: 1. Test reports shall be submitted by the contractor to the DSC. 2. The DSC shall forward a copy of the test reports to PIU for its review in its monthly report along with contractor’s monthly report. 3. The DSC shall issue a Conformance/Non-Conformance Report (CNC Report) to the contractor after review of test results by the DSC, using Format F-10 of Appendix C. The CNC reports will have a running serial number for each contract package. 4. The CNC report shall be entered in the Test Report Log by the contractor at the site, using Format F-11 of Appendix C. The details of input materials will be recorded in the Material , using Format F-12 of Appendix C. The contractor shall maintain all test records properly. Other approvals given to the contractor will be recorded in the daily logs of the contractor which should form part of the contractor’s monthly report. A recommended format for Daily Work Record/Site Order Book is illustrated in Format F-13 of Appendix C. Similar procedures shall be followed for the transmittal and review of test reports for tests performed at outside laboratories, for manufacturers’ certificates, and for third party inspection reports. (PAGE 69)



10.3 Tracking of Instructions During the process of construction, different agencies are expected to conduct site visits and instruct the contractor to ensure quality and timely construction within the costs to the extent possible. The multiplicity of agencies is a special feature of the Project. Hence there may be some ambiguity in the instruction flow if these are not transmitted and recorded properly. All the instructions to the contractor shall flow through the Engineer of the PIU. The instructions are of the following types: 1. All instructions related to the contract istration including approval of the contract variation orders, time extensions, notices related to rate of progress etc.. 2. The instructions regarding quality, testing, monitoring and work scheduling can be issued by the DSC also. In case of conflict of instructions of the PIU and DSC in these matters, the instructions of the PIU would prevail. 3. Instructions issued during site visits or inspections of the PMU, PMC, PIU and DSC, which are normally recorded in the contractor’s Site Order Book, shown in Format F-13 of Appendix C; and 4. Instructions issued during review meetings in the form of minutes, letters, etc. All instructions noted above are to be recorded by the contractor in the Instruction Log, using Format F-15 of Appendix C. Instructions also include notices of rejection of work inspected because it was found to be non-conforming to requirements and which has to be redone or rectified.

10.4 Site Order Book The Contractor shall be responsible to maintain a Site Order Book, in duplicate, at the site of the works at all times, and this shall be open for inspection by authorized representatives of RUIDP, the PMC, the PIU and the DSC. The Site Order Book has two primary purposes – to record the day-to-day instructions to the Contractor and the Contractor’s compliance with these instructions, and to record the inspection and acceptance of work completion stages along with issuing approvals to the Contractor to proceed with the next stage of construction. As noted above, the status of the Contractor’s compliance with instructions issued is to be summarized in the Instruction Log (Format F-15 of Appendix C), and reviewed monthly by the DSC/PIU and during the periodic Squad Checks. In cases where the Contractor has failed to comply with the instructions, the reasons therefore shall be determined and necessary remedial actions taken. The Engineer DSC will also maintain a parallel site Order Book to ensure compliance.

10.5 Correspondence Control Out-going letters (including transmittal letters and notes) originating from various organizations involved in the Project (PMU, PIUs, PMC, DSCs, contractors, manufacturers, etc.) shall be signed only by the designated project executive of that organization (for example PMU Director or person authorized on his behalf, PIU Superintending Engineer, PMC Team Leader, DSC Team Leader). All letters should have a reference code and number, and should refer to a single subject only, which shall be clearly stated on top of the letter, after the recipient’s address. All

(PAGE 70)



outgoing letters should be numbered sequentially. All replies should refer to the originator’s reference code and number and subject. Incoming correspondence should be stamped and dated, and preferably given an internal reference code and number. All incoming and outgoing correspondence should be logged chronologically, either in computer correspondence s or in manual correspondence logs. Copies of outgoing correspondence and originals of incoming should be filed in chronological files at the document center of each project organization. There should be only one chronological file for all outgoing correspondence. Regarding incoming correspondence, there could be more than one chronological file, based on the volume of correspondence expected to be received from project related organizations (for example IAs can maintain separate incoming chronological files for each contractor, etc.)

10.6 Inspection of Site Documentation During site visits and inspections, DSC and PIU will check and follow up with the documentation maintained on site by the contractor, as follows: •

Check the Design/Drawing and ensure that the approved designs and drawings are being used during construction.

•

Check the Test Report Log and ensure that a Conformance Report has been issued by the DSC for the materials being used.

•

Check the Material and cross-check the material test reports with inward and consumption entries of the Material .

•

Check the Instruction Log and the Daily Work Record/Site Order Book and ensure that the instructions, as recorded in these s and issued through any letters or minutes of meeting, are being implemented by the contractor.

•

Check the Daily Logs and ensure that the standard of works and documentation is of acceptable quality.

•

Deviations, if any, are to be recorded in the Site Order Book and a copy circulated by the contractor to the PMU, PMC, PIU and DSC.

•

The s that are verified by the PIU and DSC are to be signed by them.

(PAGE 71)



(PAGE 72)


11


REPORTING

This section of the QA/QC Manual outlines the Project’s requirements for progress reporting and suggests formats for reports.

11.1 Types of Progress Reports The Project provides for four main levels of reporting, as follows: 1. Contractors’ Monthly Progress Reports; 2. Design and Supervision Consultants’ (DSC) Monthly Progress Reports; counter signed by PIU. 3. Project Management Consultant’s (PMC) Monthly Progress Reports; and 4. Quarterly Progress Reports (prepared with assistance from PMC and DSC)

11.2 Reporting Schedule and Distribution The timetables for submission of progress reports and distribution requirements are summarized below.

11.2.1 Contractors’ progress reports The contractor’s Monthly Progress Report, along with his monthly running bill, shall be submitted to the DSC ( Engineer, who will give a receipt) by the 8th of the month (original plus 5 copies). To facilitate timely payment, t measurements shall be taken by the Contractor, Junior Engineer PIU and the DSC by the 7th of each month. The Engineer DSC will enter the agreed measurements. The JE-PIU will 100% measurements in MB. The reporting period would be up to end of previous month.

11.2.2 Monthly contract reports The DSC shall prepare a Monthly Progress Report for each contract, consisting of (i) a "Statement of Exceptions" commentary on the contractor's progress report, and (ii) a discussion of the major problems and actions taken or proposed to be taken. This shall be distributed, together with a copy of the Contractor's report, by the 10th of the month, to: •

PMU

•

PMC

•

PIU

The DSC would also submit the monthly running bill received by him from the PIU duly verified and entered as accepted in measurement book (DSC will make quality certification and 100% check of measurements) along with his monthly progress report copy to PIU by the 10th of each month.

11.2.3 Monthly finance reports The PIU will send a monthly finance report to the PMU by 31st of every month to report the funds receipt and utilization, statement of expenditure pending liabilities and expenditure forecasts.

(PAGE 73)



The DSC shall also prepare a Monthly Financial Report for the works consisting of (i) a "Summary Statement of Fund Utilization", and Expenditures" report(s) in the approved ADB format and submit to documentation by the 25th of each month. Copies of "Summary Utilization" are to be provided to PMC and PMU.

under his jurisdiction (ii) a "Statement of PIU with ing Statement of Fund

11.2.4 Design and supervision consultants’ progress reports DSCs shall also consolidate the contractors and it’s monthly reports into one Monthly Progress Report (This should be signed by the PIU also) for each town and distribute by the 30th of the month to.: ‰

PMU (5 copies)

‰

PIU (1 copy)

‰

PMC (1 copy)

11.2.5 Project management consultant’s progress reports The PMC shall prepare and issue a consolidated Monthly Progress Report for the Project as-a-whole by the 5th of the month to: •

PMU (5 copies)

•

PIUs (1 copy each)

•

DSC (1 copy each)

11.2.6 Quarterly progress reports Based on the monthly progress reports, PMC shall assist RUIDP in preparing and issuing Quarterly Progress Reports by the 20th of the month following the end of the Quarter for submittal to the Asian Development Bank, Empowered Committee and all involved agencies.

11.3 Report Formats Suggested formats for contractors’ and DSCs’ monthly reports are presented in Appendix D.1, D.2 and D.3 respectively.

(PAGE 74)


1

INTRODUCTION ........................................................................................................................ 1 1.1 1.2 1.3

2


BACKGROUND ......................................................................................................................... 1 QUALITY DEFINITIONS ............................................................................................................ 1 QA/QC MANUAL .................................................................................................................... 2

ORGANIZATION, RESPONSIBILITIES AND AUTHORITIES .......................................... 3 2.1 PROJECT IMPLEMENTATION ARRANGEMENTS ........................................................................ 3 2.1.1 General responsibilities ................................................................................................ 14 2.1.2 Quality assurance/quality control duties ...................................................................... 14

3

DESIGN CONTROL .................................................................................................................. 17 3.1 3.2 3.3

4

DESIGN PREPARATION PROCESS ........................................................................................... 17 DESIGN CHECKING REVIEW PROCESS .................................................................................. 17 DESIGN REVIEW CHECKLIST................................................................................................. 18

CONSTRUCTION QUALITY CONTROL – GENERAL ..................................................... 19 4.1 INTRODUCTION ..................................................................................................................... 19 4.2 TESTING ................................................................................................................................ 19 4.3 SITE INSPECTIONS ................................................................................................................. 21 4.3.1 Day-to-day supervision ................................................................................................. 21 4.3.2 Periodic quality inspections.......................................................................................... 21 4.3.3 Squad checks ................................................................................................................. 22 4.4 QUALITY CERTIFICATION AND ACCEPTANCE ....................................................................... 22

5

CONTROL OF MATERIALS AND EQUIPMENT COMPONENTS .................................. 23 5.1 5.2 5.3 5.4

6

GENERAL............................................................................................................................... 23 MATERIALS TESTED ON SITE ................................................................................................ 23 MATERIALS AND EQUIPMENT CERTIFIED BY MANUFACTURER .......................................... 29 MATERIALS AND EQUIPMENT INSPECTED BY THIRD PARTY ............................................... 31

CONTROL OF GENERAL CIVIL AND STRUCTURAL WORKS .................................... 33 6.1 CONSTRUCTION SEQUENCE AND CONTROL FLOW CHARTS ................................................. 33 6.2 TESTING OF WORKS .............................................................................................................. 33 6.3 INSPECTION CHECKLISTS ...................................................................................................... 33 1.1 ..................................................................................................................................................... 36

7

CONTROL OF ROAD WORKS............................................................................................... 39 7.1 CONSTRUCTION SEQUENCE AND CONTROL FLOW CHARTS ................................................. 39 7.2 TESTING OF WORKS .............................................................................................................. 39 7.3 INSPECTION CHECKLISTS ...................................................................................................... 39 7.4 GUIDELINES FOR PAVEMENT LAYERS .................................................................................. 52 7.5 TOLERANCES ......................................................................................................................... 54 7.5.1 Horizontal alignment tolerances .................................................................................. 54 7.5.2 Surface levels tolerances .............................................................................................. 54 7.5.3 Surface regularity of pavement courses ........................................................................ 55

8

CONTROL OF PIPELINE WORKS ....................................................................................... 57 8.1 8.2 8.3

9

CONSTRUCTION SEQUENCE AND CONTROL FLOW CHARTS ................................................. 57 TESTING OF WORKS .............................................................................................................. 57 INSPECTION CHECKLISTS ...................................................................................................... 57

CONTROL OF ELECTROMECHANICAL WORKS ........................................................... 65

(PAGE 75)


10


DOCUMENT CONTROL ...................................................................................................... 67

10.1 DESIGN DOCUMENT CONTROL .............................................................................................. 67 10.1.1 Turnkey contracts .......................................................................................................... 67 10.1.2 Item rate contracts (Wending Drawings) ...................................................................... 69 10.2 TEST REPORT CONTROLS ...................................................................................................... 69 10.3 TRACKING OF INSTRUCTIONS ................................................................................................ 70 10.4 SITE ORDER BOOK ................................................................................................................ 70 10.5 CORRESPONDENCE CONTROL ............................................................................................... 70 10.6 INSPECTION OF SITE DOCUMENTATION ................................................................................ 71 11

REPORTING........................................................................................................................... 73

11.1 TYPES OF PROGRESS REPORTS .............................................................................................. 73 11.2 REPORTING SCHEDULE AND DISTRIBUTION .......................................................................... 73 11.2.1 Contractors’ progress reports ....................................................................................... 73 11.2.2 Monthly contract reports ............................................................................................... 73 11.2.3 Monthly finance reports ................................................................................................ 73 11.2.4 Design and supervision consultants’ progress reports ................................................. 74 11.2.5 Project management consultant’s progress reports ...................................................... 74 11.2.6 Quarterly progress reports............................................................................................ 74 11.3 REPORT FORMATS ................................................................................................................. 74

(PAGE 76)

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