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WELCOME TO TRAINING PROGRAMME FOR

WELCOME TO TRAINING PROGRAMME FOR CONSULTANTS’ SERVICES FOR 3 rd PARTY QUALITY CONTROL AND QUALITY ASSURANCE. G. PRABHAKAR. CHAPTER 1. QUALITY MANAGEMENT SYSTEM. Quality Planning. Quality Control. Quality Assurance. Quality Audit and Quality Improvement. Design Drawings

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WELCOME TO TRAINING PROGRAMME FOR

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  1. WELCOME TO TRAINING PROGRAMME FOR CONSULTANTS’ SERVICES FOR 3rd PARTY QUALITY CONTROL AND QUALITY ASSURANCE G. PRABHAKAR

  2. CHAPTER 1

  3. QUALITY MANAGEMENT SYSTEM Quality Planning Quality Control Quality Assurance Quality Audit and Quality Improvement • Design • Drawings • Specifications • Staff • Training • Laboratories • Site Organization • Debris disposal • testing of Materials at source • Borrow areas • Mix designs • Quality Control Manual • Pre Construction Activities • During Construction Activities • After construction Activities and curing • Inspections • Sampling • Testing • Reporting • Control charts • Documentation soft & Hard copies • Photographs records • Video film records. • Scrutiny of Reports and tests data • Improvements required

  4. SALIENT ASPECTS OF QUALITY ASSURANCE & QUALITY CONTROL CONSULTANCY FOR NSP MODERNIZATION & REHABILITATION WORKS UNDER APWSIP Y. BABU RAO, FIE; M.Tech; MIGS; ISRM.

  5. PREAMBLE In order to attain the best and sustainable quality of construction, Govt. and World Bank desired to appoint. THIRD PARTY QUALITY ASSURANCE/CONTROL CONSULTANTS to work in coordination with the Project Engineers.

  6. PRINCIPLES OF QUALITY • Quality planning prevents pathetic performance. Quality lives on long after the price is forgotten. • What is Quality? • Fit for purpose, suitable for the intended purpose.

  7. PRINCIPLES OF QUALITY • Many experts defined Quality in many ways. • JURAN (father of Quality guru) defined that • A greater number of features that meet customer needs and has • Fewer deficiencies.

  8. PHILIP CROSBY defined that • Quality is that which meets every possible technical specifications and it consists of: • 1. Design • 2. Make it, test it • 3. Use it • Test it in service • EDWARD DEMING defined as conformance to requirement

  9. QUALITY PLANNING • to establish quality goals. • to identify the needs of work • to develop process which enables to produce the desired specifications. • to establish process controls

  10. QUALITY IMPROVEMENT • to establish infrastructure. • to establish project team. • to provide the team with resources training.

  11. QUALITY ASSURANCE • Assurance: The act of giving confidence, the • State of being certain or the act of Making certain. • Quality Assurance: The planned and systematic • activities implemented in a quality system so that quality requirements for a product will fulfilled.

  12. QUALITY ASSURED BY QUALITY ASSURED BY • QUALITY CONTROL • CONTROL: An evaluation to indicate needed corrective responses, the act of guiding a process in which variability is attributable to a constant system of chance causes. • QUALITY CONTROL: The observation techniques and activities used to fulfill requirement for quality.

  13. PARTIES INVOLVED IN THE WORK TO ENSURE QUALITY • PARTY – I: Project Engineers • PARTY – II: Construction Agency • PARTY – III: Quality Assurance Consultants

  14. CONTRACTOR AND PROJECT ENGINEERS • PROJECT ENGINEERS: • are primarily responsible for Quality Assurance of the work being executed and to conduct all field tests before allowing further work. • Shall check and produce to inspecting officers the following records and O.K. Cards maintained by the Construction Agency.

  15. a) Registers:- • 1. Site order. • 2. Register of Bench Marks • 3. Material O.K. Register. • 4. Register of foundations. • 5. Register of placement for concrete, Embankment, Reinforcement and other test reports. • 6. Register of test reports of compressive strength of concrete specimens. • Cement day Book. • Register for embankment placement • Roller press control register • Moisture Control Register • Embankment test results register • Register for shot crete • Register for Aggregate testing

  16. b) O.K. Cards for Big Structures and Heavy Embankments: • 1. O.K. card for cast-in-situ concrete lining. • 2. O.K. card for Earthwork Embankment • 3. O.K. card for grouting • O.K. card for structural concrete work. • O.K. card for sub-grade preparation. • O.K. card for RR Masonry • O.K. card for shot creting • O.K. card for grouting

  17. AE/AEEs have to check pre levels and final levels. • For measurements recorded by Construction Agency, D.E.Es to test check measurements spread over the entire work. E.Es/S.Es to check measure as per Codal provisions and rules in vogue. • The measurement records have to be maintained by Construction Agency and finally handed over to the Engineer-in-Charge.

  18. The observations made by Third Party Quality Control, Department Quality Control Staff have to be invariably complied with before the next bill for payment is presented. To this effect certificate has to be recorded by Construction Agency and countersigned by the field engineers.

  19. It will be better if the Monthly review meetings are conducted by the concerned SE’s invariably involving Quality Control and construction agencies to discuss the Quality Assurance aspects and record the minutes of the said meetings.

  20. QUALITY CONTROL STAFF • Shall verify the records maintained at site by the E.P.C. agency and the Third Party Quality Control Consultants. • The TPQC Consultant shall witness and verify 10% tests being carried out by contractor. • Shall associate with construction staff or conduct independently 10% tests with required frequency as per specifications.

  21. QUALITY CONSULTANTS • The Third Party Quality Assurance Consultants should posses all the testing independent testing to assure the Quality of work. • Quality requirements should be clear and verifiable.

  22. DESCRIPTION OF TASKS • Review of Design, plans and specifications for constructability and operability. • Important decisions regarding Quality of works are made during design and planning stages. Quality Assurance during construction depends on conformance to the design and specifications.

  23. consultant to participate in designs review meeting with project engineers and contractor’s representatives and give suggestions, if any………………..

  24. CONSULTANT TO PROVIDE • Services enabling the Government to ensure best Quality of Construction in the Project by working closely with the Field Engineers. • TASKS TO BE PERFORMED BY THIRD PARTY • Review of Designs and Drawings HPs, Designs of Structures & Specifications and Review of QMP of EPC Agency.

  25. Review Contractor’s Test Data & Conduct tests in selected frequency. • Review of Mix Design • NDT Data on finished items • Non-Conformities – Corrective action • Calibration Report • Quality Certificate • Inter Lab Testing

  26. CALIBRATION OF TESTING CEMENT • QA consultant to verify calibration of all their and Contractor’s testing and measuring equipment – reports on calibration status, frequency of recalibration etc. to be submitted to the Engineer-in-Charge. • The qualifications, experience of the testing personnel have to be assessed.

  27. QUALITY MANAGEMENT SYSTEM • Quality of the work is dependent upon the participating constituents, some of which are sustainable and effectively controlled while others are not. • The process of managing the quality is through QMP.

  28. QUALITY MEASURES • Periodic inspection, testing and verification. • Proper maintenance of records and registers. • Undertaking quality audit and review of QMP and QAP. • Provide training to all concerned.

  29. STAGES FOR INSPECTION, TESTING AND VERIFICATION • Input Materials Inspection. • During Construction Inspection • Completed work inspection.

  30. Evaluate establish the contractor’s QMP (Quality Management Plan) requirements to see whether the Q.C organization possesses the following standards: • 1) Evaluation of Testing and Inspection efficiency. • - Effectiveness of procedures • - Operation of Plant and Equipment • - Adequacy of personnel and • - Progress of records

  31. 2) Evaluation of Internal assessment: • - Information that is adequate and accurate • - Effectiveness of communication and feed back of Quality Control decisions to the operation level. • - Control overall phases of operation. • 3) Evaluation of overall performance of various Project Laboratories: • Procedures being followed • Performance of individual laboratories • Inter-Laboratory testing

  32. COMPLIANCE • Procedures and controls are of no significance unless meticulously followed. It shall be ascertained through. • Inspection and visual observation (Ex. Concrete lining in place, structural concrete in place etc and supplementing it by appropriate tests). • Examination of O.K. Card. • Persual of control charts for cement and concrete • Direct Enquiry.

  33. VERIFICATION • Consultant shall review the facilities and staff in labs. to determine whether • the personnel possess adequate knowledge of testing procedures and • the testing and inspections are adequate.

  34. MONITORING CONTRACTORS PROCEDURES FOR TESTING DEFICIENCIES TO ASSURE CORRECTIVE ACTION TAKEN – QUALITY AUDIT • Construction Deficiencies and non-conformaties. • Report to the engineer to ensure that new work is not placed on unacceptable work.

  35. LABS – TEST RESULTS • Depend on • Competency of the testing personnel • Accuracy of the apparatus and equipment • Maintaining special environment conditions • Proper maintenance and periodical calibration of testing machines. • Lastly knowledge in interpretation of test results.

  36. PRE CONSTRUCITON CHECKS • INPUT MATERIALS • Trained personnel with necessary equipment to verify for required specifications and the recommend for acceptance. • Clear GUIDELINES to be drafted for inspection requirements, sample plans and acceptable quality levels. Test results and certificate of conformance to be furnished to Engineer-in-charge.

  37. Corrective Action Notice to be issued by Consultant when material fails to conform to specifications. • To inform the Engineer-in-Charge whether the material is passed or failed.

  38. QA CHECKS – ON GOING WORKS • To ensure the materials, construction works are as per specifications of APSS and IS codes. • Defect prevention is preferred to detection after occurrence.

  39. CONDUCT TESTS AT THE WORK SITE • Consultants to maintain confidentiality as regards the sample testing. • For reconciliation, the Engineer-in-Charge discusses with consultants and contractors. • QA Consultant to organize inter-laboratory testing sample with NCCB and APERL for establishing the competence of project laboratories. • This should be done once in THREE Months.

  40. THANK YOU

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