Вы находитесь на странице: 1из 53

Rehabilitation and Upgrading of Pakpattan Canal,

Khadir Branch and Pakpattan Islam Link


Contract: PCSBIP/ICB-01

CONTENTS
1

INTRODUCTION............................................................................................... 2
1.1

QUALITY POLICY........................................................................................ 2

1.2

QUALITY OBJECTIVES................................................................................2

1.3

POLICY REVIEW......................................................................................... 3

1.4

MANAGEMENT RESPONSIBILITY................................................................4

1.5

QUALITY SYSTEM AT SITE..........................................................................6

QUALITY ASSURANCE PLAN............................................................................. 7


2.1

CONTRACTORS SUBMITTALS....................................................................8

2.2

EARTHWORK........................................................................................... 12

2.3

CONCRETE WORK................................................................................... 15

2.4

STONE PITCHING & STONE APRON..........................................................18

2.5

BRICKWORK............................................................................................ 16

QUALITY CONTROL PLAN............................................................................... 18


3.1

PREFACE.................................................................................................. 18

3.2

DOCUMENT CONTROL.............................................................................18

3.3

PROCUREMENT CONTROL.......................................................................19

3.4

CONSTRUCTION MATERIAL CONTROL.....................................................20

3.5

PROJECT PROCESSES.............................................................................. 21

3.6

CALIBRATION OF VARIOUS DEVICES / EQUIPMENT..................................24

3.7

TEST PROGRAMME.................................................................................. 24

3.8

QUALITY RECORDS.................................................................................30

3.9

TRAINING................................................................................................ 33

3.10 INTERNAL QUALITY AUDITS.....................................................................34

Page | 1

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

INTRODUCTION

The Punjab Irrigated Agriculture Investment Program (PIAIP) is being financed jointly by the
Asian Development Bank (ADB) and the Government of Punjab. The Investment
Component of PIAIP includes Rehabilitation and Upgrading (R&U) of Pakpattan Canal,
Khadir Branch and Pakpattan Islam Link. After a Process of International Contract Bidding
(ICB), the contract is awarded to M/s Sinohydro NEL Joint Venture on the basis of fulfilling
the international standards of expertise in construction.
1.1

QUALITY POLICY

It is the policy of SINOHYDRO-NEL Joint Venture, to supply work and services of high and
consistent quality to its Clients. These will be in accordance with the SINOHYDRO-NEL
Joint Venture organisational goals, Clients requirements and expectations. This policy will
be reviewed at regular intervals to ensure that it is still up to date and relevant.
All operations shall be carried as per Standard Operating Procedures or Technical
Specifications provided by the client. Deviation from the procedures and specifications must
be first notified to the Management. Management is responsible for final approval of all
changes to procedures prior to implementation.
It is part of the SINOHYDRO-NEL Joint Venture training programme that this policy is
understood, implemented and maintained at all levels in the organisation.
This statement represents our commitment, on behalf of SINOHYDRO-NEL Joint Venture
to the Quality Policy.
Responsibilities
Project Manager is responsible to implement this policy at site.
1.2

QUALITY OBJECTIVES

Following are the Quality objectives based on the SINOHYDRO-NEL Joint Venture Quality
Policy;

Adherence to work schedules on time, each time.


To propagate the company Quality Assurance and Safety policy objectives at site.

Ensure the highest level of quality by maintaining supervised controls and written
instructions governing Quality Control procedures & practices.
Establish clearly defined responsibilities for compliance.

Page | 2

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Meet contractual requirements by conformance to Contract Documents and


applicable standards.
Complete & maintain accurate records of inspections and tests.
Ensure that corrective action is properly implemented and documented.
Maintain procedures to ensure that quality requirements are communicated to all
levels, including sub-contractors.
Provide healthy working and living environment at site and ensure our Safety targets
of Zero Accident, Zero Injury and Zero Property Damage.
Enhance working skills of personnel through formal on-the-job and planned training.

The Quality policy and Objectives are to be circulated to all departments and section Incharges at site, who will be responsible for its understanding, promulgation and
implementation. The Quality Policy is to be displayed at all the prominent places to facilitate
maximum exposure to the SINOHYDRO-NEL Joint Venture employees.
1.3

POLICY REVIEW

Policy Review responsibility at site is through a review committee consisting of PM and Incharge of the sections. This review committee is to periodically coordinate and control the
activities of the Quality System being carried out at site, review and evaluate the
performance of the Quality System and attainment of Quality objectives. The maximum
period between Policy Review meetings is two months. However, the meeting may be called
at any time when it is considered necessary on the direction of PM.
The agenda of the Policy Review meeting is prepared by QA/QC Manager in consultation
with the PM and distributed to the review committee well in time. The agenda covers but is
not limited to the following points:

The progress monitoring of execution activities.


The organizational structure, including the adequacy of staffing and resources.
The structure and degree of implementation of the Quality System.
External / Internal Audit Reports.
Discussions on the causes for non-conformities and verification of the resulting
corrective / preventive actions.
Customer complaints.
Vendor / subcontractor Performance.
Other Site Issues.

Meeting Proceedings
Meeting is to proceed in the following manner:

Follow-up of the decision made in the previous meeting.


If implementation is successfully achieved on previous decision, it is then eliminated
from the agenda otherwise the reason for non-implementation is discussed and a
remedial corrective action is decided.
Point wise discussion as per Agenda.

Page | 3

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

New points recorded with decisions on necessary actions and assigning of


responsibilities for corrective and preventive actions against a target date.

Record of the Meetings


The minutes of the Policy Review meeting is to be recorded and distributed to all concerned
persons for follow-up. The minutes include the name of persons who attended the meeting,
matters reviewed, decisions taken on required actions, the names of persons responsible for
implementing such actions and the dates by which they are to be completed.
1.4 MANAGEMENT RESPONSIBILITY
The project specific organogram for site is placed at Annexure-A
Project Manager
The Project Manager together with his key functionaries have the declared responsibility for
implementing the Quality programme in their respective areas of responsibility and
operation. Brief Job Descriptions (JDs) is given below for the key functionaries at Site.

He is responsible to prepare the Project Quality Plan and implementation of the


project organization, execution, safety and quality plans.
He keeps liaison between the Consultant, Client and Project team for overall
directions.
Plans construction programs and schedules for field execution operations in
accordance with contractual requirements.
Approves corrective and preventive actions on non-conformities.

Site Manager
He reports to the Project Manager for execution of production/construction, safety
and quality plans in his area of execution.
Helps in the preparation of Project Quality Plan in consultation with concerned
departments.
Controls & Supervises construction activities in his area of responsibility in
accordance with contractual requirements.
Co-ordinates with the field support groups, QA/QC and Safety for execution.

QA/QC Manager
The Quality Control (QC) Manager will be responsible for overseeing overall implementation
of Quality Control Plan and will coordinate all project testing, inspections and reporting
matters directly with the Project Manager and Site Manager. The QC Manager and all
workers have the authority to intercede directly and stop work due to any unsafe work
practices or site conditions.
Duties

Preparation, approval and implementation of the QA&QC Plans.


Verification of Material as per project Specifications.
Page | 4

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Inspection of delivered materials as per Project Specifications and Relevant


standards.
Co-ordination with Independent labs for conducting different test according to project
specifications.
Ensure that all materials and construction are in accordance with the requirements
for the completeness, accuracy, constructability in compliance to the requirement of
Contract Documents.
Documentation for material and administrative approvals and backups.
Carry out and participate in weekly progress and QC Meetings.
Manpower adequacy checking as per scheduled activities.
Supervision of Quality Inspectors for different Inspection activities.
Inspection of Civil works executed by Sub-Contractors.
Ensure to carry out all work in a safe manner in accordance with site rules and
regulations.
Carry out quality control checks as defined on quality plans as directed by Project
Manager.
Witness critical installation activities as defined on contractor's quality plan.
Ensure that works are coordinated in an effective manner so that programmed
objectives are achieved.

Construction Manager
Construction Manager reports to Site Manager and is responsible to ensure accomplishment
of field activities in accordance with approved Methodology & specified requirements.
Manage construction field activities with the help of Site Engineer & supervisors. Coordinates with QA/QC for inspections, testing and identification of root causes against nonconformities.
Planning Engineer
Planning Engineer reports to the Site Manager in his discipline and is responsible to
schedule & detail planning of Resources against the specified scope of work. Monitor and
Control progress maintaining & reporting. Preparation and approval of execution
methodology from Consultant. Overall Control of Documentation flow to concerned sections.
Co-ordination among concerned departments, sections, Consultant and Client for necessary
arrangements and resources allocations.
Manager Admin
Manager Admin reports to Site Manager and is responsible to establish and maintain
administration system at site. Maintain personnel records, increments and pay allowances.
Co-ordinates with labor and social security departments. Ensures arrangements of
communication, transport, accommodation, messing, furniture and proper protocol for
guests and visitors.
HSE Manager

Page | 5

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

HSE Manager functionally reports to Head Safety and administratively to Site Manager and
is responsible to implement the Project Environmental Management Plan, SSEMP, safety
policy and Site HSE Plan. He is responsible to organize the Safety training program, ensure
availability of P.P.E, fire-fighting equipment. Preparedness for accidents & crisis
management.
Resource Management
All resource requirements at site are assessed on the basis of resource plans based on
contract specifications. These resource plans are used for identifying, estimating, scheduling
and allocating relevant resources. These plans are subject to multiple revisions, depending
upon the actual usage requirements. For further details please refer to Project Process
Control.
1.5

QUALITY SYSTEM AT SITE

PURPOSE
The purpose of the Quality System at site is to establish and maintain SINOHYDRO-NEL
Joint Venture Consultant and Client specified Quality management system at Site.
RESPONSIBILITY
The PM at site is responsible to establish and maintain the Quality System. SINOHYDRONEL Joint Venture Quality System is based on a hierarchy of the Quality Policy, QA / QC
Plan, Specifications, Procedures & Methods, Analysis of Project Quality Records and Policy
Review.

Quality Policy & Objectives

QA / QC Plan

Specifications, Procedures & Methods

Analysis of Project Quality Records

Policy Review

Page | 6

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

QUALITY ASSURANCE PLAN

This Quality Assurance Plan (QAP) is an effort to outline the activities of the
SINOHYDRO-NEL Joint Venture in adequate details for the guidance of its staff and
other relevant Personnel during the construction activities of the project to satisfy
the requirements of Contract. It requires that individuals have clearly defined
responsibilities and lines of communication to enable all aspects of the work activities to be
assessed and accepted and if a problem is discovered, the solution is quickly found. QAP
cannot replace the experience of reasonable and responsible staff; however it can help them
in selection of timely and sequential line of various activities and in keeping and maintaining
retrievable record documentation. This QAP is specially designed for Rehabilitation and
Upgrading of Pakpattan Canal, Khadir Branch & Pakpattan Islam Link Project (Contract No.
PCSBIP/ICB- 01).
The SINOHYDRO-NEL Joint Venture is, in particular, responsible for the Quality
Control of the Works as per Contract Specification. Consultants supervision and
surveillance does not relieve the Contractor of his contractual obligations. The basic
purpose of QAP is to ensure that the Quality Control System is in place and
performing to the requirements of Contract documents during the construction
period.
The quality requirements are based on provisions for technical specifications as per contract
documents for Rehabilitation and Upgrading of Pakpattan Canal, Khadir Branch &
Pakpattan Islam Link Project. Maximum efforts have been exerted in making QAP an
acceptable and tangible document for all levels of execution and supervisory staff and
novice to experience. Technical notes are provided at places to develop field staffs
approach and insight for a useful and effective supervision, without undermining adherence
to the contract specification.
The Contract Documents are the basis for this QAP, therefore, where an ambiguity is
detected between the procedures and requirements of QAP and content of Contract
Documents then the later takes the precedence.
The following are the objectives while formulating QAP.

To define and adopt a sequential and systematic quality assurance line of action with
participation of the other stake holders for ensuring of all submittals, procurement,
execution of works and other on and off site construction activities. These activities may
Page | 7

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

also include material supply, testing and reporting envisaged in the specification of the
project.

To maintain auditable record of all tests, inspections, procedures and corrective


measures and any other information considered helpful.

To define the assignment and responsibilities of the Contractors field staff and other
relevant personnel at site with respect to Quality Assurance of the project vis-a-vis the
Contractors Quality Control Programme and their interaction with the client and the
Consultant.

To prevent non-conformities through proactive Quality Assurance.

2.1
2.1.1

CONTRACTORS SUBMITTALS
Objective

The objective of this Section is to guide the field staff of the SINOHYDRO-NEL Joint
Venture regarding different submissions to be made in the form of check requests, test
requests, approval requests and authorization requests for execution of work. These
submissions will be made by for methodological construction execution works.
2.1.2

Applicability

The Contract Documents for Rehabilitation and Upgrading of Pakpattan Canal, Khadir
Branch & Pakpattan Islam Link Project require the Contractor to submit certain documents
to the Consultants, i.e. before, during and after the execution of the works. These
documents / write-ups may include;

Work Programmes (As per Contract specifications)

Quality Control Test Results (As per Contract specifications)

Drawings and data for Equipment (As per Contract specifications)

Installation Instructions for Equipment (As per Contract specifications)

Operation and Maintenance Manual for mechanical equipment (As per Contract
specifications)

Manufacturers Certificates for various Construction Materials like water stops, bearing
pads, expansion joint fillers and sealants.

The submittals for various items of Project Works are provided in the checklist CKL-1.1
Checklist for Contractors Submittals for the guidance of the Contractors field staff.
Page | 8

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

CKL 1.1 (1) CHECKLIST FOR CONTRACTORS SUBMITTALS


General
Sr. No.

Document Format

Time For Submission

Contractors work
Programme including
arrangements, order
and timings

Contractors Format

Within 28 days of delivery


of LOA* and updates
when required

Details of the
Programme and
Resource Schedule

Contractors Format

1.3

Request for Survey


check by the Contractor

Contractors Format

Prior to commencement
of works

1.4

Contractors Quality
Control Programme

Contractors Format

Prior to commencement
of works

1.1

1.2

Submittal

As per Specification

As per Specification

Within 28 days of delivery


of LOA

These submissions shall be made by the Contractor to The Engineer for prior detailed
review and agreement/advice.
* Letter of Acceptance.

Page | 9

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

CKL 1.1 (2) CHECKLIST FOR CONTRACTORS SUBMITTALS


Earthworks and Caring & Handling of Water
Sr. No.

Submittal

Document Format

Time For Submission

2.1

Plan for Diversion


Works*

Contractors Format

Prior to Construction of
diversion works

2.2

Materials Source
Approval*

Contractors Format

Prior to commencement
of component of work

2.3

Quality Control/
Assurance Tests to be
submitted direct to The
Engineer

Contractors Format

As per requirements of
specifications and QAP

2.4

SSEMP for Borrow


Area.

Contractors Format

Prior to start of
Construction.

These submissions shall be made by the Contractor to The Engineer for detailed
review and agreement/advice.

Page | 10

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

CKL 1.1 (3) CHECKLIST FOR CONTRACTORS SUBMITTALS


Concrete Works

Sr. No.

Submittal

Document Format

Time For Submission

3.1

Method Statement

Contractors
Format

Prior to Construction

3.2

Mill test Certificates for


Steel Reinforcement

Manufacturers
Format

Along with delivery of


steel at site

3.3

Bar Bending Schedule

BB-01

3 days Prior to
Commencement of
fabrication of Re-Steel

3.4

Quality Control Tests for


Concrete works

Ref. to section 3.7.

As per requirements of
specifications.

3.5

Manufacturers Certificate
for Rubber water stops,
bearing pads joint filler
and sealants

Manufacturers
Format

Prior to procurement

3.6

SSEMP as per EMP


requirements

Contractors
Format

Prior to start of
Construction

These submissions shall be made by the Contractor to The Engineer for detailed
review and agreement/advice.

Page | 11

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

2.2

EARTHWORK

2.2.1

Objective

Objective of this Section is to provide the recommended guidelines to the Sinohydro-NEL


Joint Venture field staff for their guidance in performing quality assurance of earthwork for
structures and for the canal embankments etc. pertaining to the Permanent Works
This Section covers the open cut/foundation excavations, foundation backfills for the
structures and earthwork for irrigation canal embankments. The recommended guidelines
can also be used for other similar works and earthwork required for diversion arrangements.
2.2.2

Construction Equipment

Selection of type of excavation and compaction equipment must be done wisely keeping in
view the bulk of work and efficiency of the equipment and that the selected equipment is
capable and adequate to perform the required earthwork. The following may be deployed as
per the nature of work involved;

Excavators

Dozer

Tractors with implements

Front End Loaders

Dragline Excavators / Cranes

Dump Trucks

Motor Graders

Water Bowser

Dewatering Arrangements

Compactors(Rollers)

Flood Light Arrangements

2.2.3 Inspection
Setting out details on site as per design will be the responsibility of the field staff. The
Consultants through their own field staff shall check the setting-out accuracy, survey
control for NSL and design levels by joint survey with Contractor. These surveys shall be
Page | 12

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

carried out by Contractors surveyors in the presence of Consultants Inspectors. The


site inspector .shall monitor the excavation slopes for stability and compaction of the sub
grade and fills, etc.

If the Contractor encounters wet or slush, he is required to report to the Consultants Site
Engineer who will jointly inspect the site, evaluate according to Earthwork Sub Clause of
Technical Specifications of Contract Documents and submit their recommendations for
approval by the Engineer.

The Control of moisture and compaction of soils in the embankment of canals and
compacted earth consists of inspection of the material used, checking the amount and
uniformity of the soil moisture, maintaining the thickness of layer, and finally determining
the percentage of relative Dry Density of the compacted fill.

The relative Dry Density of the compacted fill is determined on the basis of Field Density
Tests and the Reference Laboratory Compaction Tests. The Field Density Tests shall be
performed by the Contractors staff as and when directed by the Engineer In-charge or
Site Inspectors.

Tests at critical areas shall be carrying out by Consultants staff and verified in
Consultants Field Laboratory.

The Standard/Modified Proctor Compaction Tests are used as Reference Laboratory


Tests for fine grained clayey soils. These tests shall be performed at the Contractors
Field Laboratory.

The Maximum and Minimum Dry Density Test results (from external laboratory) are used
as Reference Laboratory Tests for cohesion less sandy soils.

The soils having less than 12% passing No. 200 sieve are defined as sandy or noncohesive soils.

The Site Inspector should see that all perishable matter and any soil which may become
unstable upon saturation, such as highly organic soils, loose silts, very fine sands/silts
and expansive clays etc. are not present in the foundations. These soils either need to
be removed or improved to the extent necessary to provide a safe, stable foundation or
sub-grade under operating conditions.

A good bond between the foundation and first layer of fill is achieved by moistening the
foundation rather than using a very wet embankment layer.

Page | 13

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

For Quality Assurance (QA) of earthwork operations the Staff shall proceed in
accordance with CKL-1.2(1) Checklist for Structural Excavations and CKL-1.2(2)
Checklist for Canal Earthworks.

An important function of inspection is to determine when and where to make Field


Density Tests. These tests should be made in areas where degree of compaction is

doubtful.
Areas of doubtful density are sometimes detected by observation. Possible locations of
insufficient compaction include:

The junction between areas of mechanical tamping and rolled earth fill
embankment along abutments or cut-off walls.

Areas where rollers turn during rolling operations.

Areas where too thick layer is being compacted.

Areas where improper moisture content exists in the soil.

Areas where less than specified number of roller passes were made.

Areas where oversized rock which has been overlooked, is contained in the fill.

Areas containing material differing substantially from the average.

2.2.4

Specified Limits for Degree of Compaction


While performing control over compaction the limits given below from specifications
should be observed.
Compaction Requirements

Description

Backfill around
Structures above
foundation level

Special Backfill
and Fill beneath
Structures
(Foundations)
Foundation under
Canal
Embankment /
Sub-grade for
Lining
Canal

Cohesive Soils

90% Modified Proctor Dry


Density

95% Modified Proctor Dry


Density

90% Modified Proctor Dry


Density

90% Modified Proctor Dry

Cohesionless
Soils
70% Relative
Density
80% Relative
Density

70% Relative
Density
70% Relative
Page | 14

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Embankments
(Main or Branch)
Disty/Minor
embankments

Density

90% Modified Proctor Dry


Density

Density

70% Relative
Density

Page | 15

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

2.2.5

Frequency of Control Tests

The recommended tests, their procedures, frequency and the required facilities
for an effective quality control/assurance of earthwork are presented in Section
3.7 Test Programme. The contractors field staff is required to ensure that these
tests are performed as per specified frequencies in the recommended
laboratories or at site. The field tests should be performed in the presence of the
Engineers site Inspector and the results recorded immediately on completion of
the test, duly signed by the authorized representative of the Contractor and
Consultants. An independent record of the tests should also be maintained
by consultants field staff, in addition to the submittals of the Contractor.

S
1.

2.

3.

4.

CKL 1.2 (1) CHECKLIST FOR STRUCTURAL EXCAVATIONS

Issues

Record/Re
porting
Document

Level of TBMs established by the


Contractor, Confirm by Survey
Control.

NSL by checking of the survey


data and record entries. Check
and approve by Survey Control.

Engineers
Rep.

Complete setting out/layout.


Check by Survey Control and
Dimensional Inspection.
Location and level of level pegs,
Check by visual inspection and
Survey Control.

Action by

Survey &
Level
Book and
Ref. to
Section 3.7

Contractors
Surveyor

5.

Location of spoil or dump for


excavated material. Optional
Check by Visual Inspection.

Lab
Technician

Ref.
Section 3.7

6.

Deployment
Equipment.

Lab
Technician

Ref.
Section 3.7

of

proper

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

7.

8.

Adequate dewatering to desired


levels, before start of excavation
below water table. Water level to
be maintained 3 ft. below the
lowest foundation level. Ensure
by physical inspection

Lab
Technician

Ref.
Section 3.7

Complete
information
about
condition of soil i.e. dry, wet or
slush.
Check
by
physical
inspection
and
record
observations.

Lab
Technician

Ref.
Section 3.7

Lab
Technician

Ref.
Section 3.7

9.

Stability of excavated slopes.


Ensure by physical inspection.

10.

Final
levels
of
excavated
surfaces and record entries.
Check by Survey Control and
make record entries.

Engineers
Rep.

Contractors
Surveyor

Survey &
Level
Book and
Ref.
Section 3.7

All actions should be taken in accordance with the Contract Specifications and
Contractors Work Methodology as approved by the Engineer.

1.

2.

3.

CKL 1.2 (2) CHECKLIST FOR CANAL EARTHWORKS

Issues

Action by

Record/Re
porting
Document

Level of TBMs established by


the Contractor to be checked
jointly.

NSL by checking of the survey


data and make record entries
by Joint Survey.

Complete setting out/layout.


Check by Survey Control and
Dimensional Inspection.

4.

Location and level of level


pegs, Check by spot visual
inspection
and
Survey
Control.

5.

Final

levels

of

excavated

Engineers
Rep.

Contractors
Surveyor

Survey &
Level
Book and
Ref. to
Section 3.7

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

surfaces. Check by Survey


Control.
6.

Deployment
equipment.

Lab
Technician

Ref.
Section 3.7

7.

Clearing,
Grubbing
and
Stripping. Ensure by physical
inspection.

Lab
Technician

Ref.
Section 3.7

8.

Approval of backfill material


(excavated
or
borrowed).
Check by physical Inspection
or Test Procedures.

Lab
Technician
Field Lab.

Ref.
Section 3.7

9.

Compaction control during


execution Check by physical
Inspection
and
Test
Procedures.

Lab
Technician

Ref.
Section 3.7

10.

Lab
Technician

Ref.
Section 3.7

of

proper

Records of all Tests made


during time period. Update
periodically.

All actions should be taken in accordance with the Contract Specifications and
Contractors Work Methodology as approved by the Engineer.

2.3

CONCRETE WORK

2.3.1

Objective
Objective of this section is to provide the recommended guidelines, sequential
inspection procedures and other relevant information to the field staff of the
Contractor for their guidance in quality assurance of reinforced concrete and prestressed concrete pertaining to the permanent works being executed at site.

2.3.2

Applicability
This section covers Plain Cement Concrete (P.C.C.), Reinforced Cement
Concrete (R.C.C.) and pre-stressed concrete works for permanent structures as
well as pre-cast works as shown on the drawings and as directed by The
Engineer.

2.3.3

Construction Equipment
The Contractor must ensure that the equipment is adequate to perform the
concrete work.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

2.3.4

Inspection

1) For quality assurance of construction activities the Consultants Supervisory Staff


shall proceed in accordance with CKL-1.3 (1) Checklist for concrete work.
2) For effective Quality Control, the Contractor is required to perform certain tests at
different stages of the concreting process. These tests include tests to be performed
on concrete ingredients, before start of the concreting works, tests to be performed
during construction stages and the tests to be performed subsequently in the
Contractors Field Lab. or in any other approved external laboratory.
3) A list of tests, the test procedures, test frequencies and the proposed testing
arrangements are provided in Section 3.7 Test Programme.
4) The required Record/Reporting Documents for the Consultants Field Staff are also
listed in Section 3.7 Test Programme.
5) To maintain an auditable and retrievable record of all Inspection Tests, Noncompliance and Corrective Actions etc. the provided proformas must be used by the
Consultants Supervisory Staff.
6) The Engineer is to ensure that the required tests are performed by the Contractor in
accordance with the specified procedures and in the presence of his representative.
He is required to maintain a complete record of these test results independently.
2.3.5

Classes of Concrete
Concrete for several structures and part thereof shall have 28-day compressive
strength of 6 12 cylinders at least equal to the minimum allowable strength
shown in the following Table:

Cl

Compressive Strength at 28-days

Cylinder Strength

N/mm2

4000 Psi

27.58

3000 Psi

20.67

1500 Psi
10.34
C
* Actual Mix Ratio will be determined after Concrete Mix Design carried out in
accordance with relevant Sub-Clauses of Technical Specifications of Contract
Documents.

2.3.6

Nominal Maximum Aggregate Size

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

The nominal maximum aggregate size to be used in various structural


components shall be as follows: (Technical Specifications 6.5)

Lean Concrete

Maximum dimension of Structure less


than 12
Maximum dimension of Structure more
than 12

General Use

Nominal Maximum
Aggregate Size

"

"

2.3.7

Concrete Mix Design


The mix proportions for class of concrete mentioned in the specifications are
nominal. The concrete mix design is required to be carried-out by the contractor
under supervision of Engineers representative at field laboratory using cement,
sand and aggregates from the approved source of supply. Required average
strength used as the basis of selection of concrete proportion, shall be in
accordance with ACI 318.

The concrete mix design for each class of concrete in addition to mix proportion
will also provide water-cement ratio by weight (exclusive of water absorbed by
the aggregate) which will be determined on the basis of producing concrete
having suitable workability, density, impermeability, durability and the required
strength.

2.3.8

Concrete Pour Authorization


The contractor is required to submit Concrete Pour Authorization (CPA) Request
(Refer to Section 3.7 Test Programme) before starting concrete for any
component of a structure. The Engineer should check all the items, before
allowing pouring of concrete. In case of deficiency, that would be marked on the
CPA slip and returned to the Contractor for rectification. The same CPA slip will
be finally signed on satisfactory rectification. One copy will be retained by the
Engineer for reference and record. Contractors copy should be kept at site by the
Contractor.

CKL 1.3 (1) CHECKLIST FOR CONCRETE WORKS

Issue

Actio

Record/Re

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

n by

Physically
inspect
all
the
Reinforcement Steel procured by the
contractor and confirm adherence to
the
Specifications
by
Test
Procedures.
Physically inspect, cement procured
by the contractor and confirm
adherence to the Specifications by
Test Procedures.

Lab
Tech
nicia
n

Lab
Tech
nicia
n

Physically inspect, fine and coarse


aggregates and confirm adherence
to the Specifications by Test
Procedures.
Deployment of proper equipment.
Discuss with Contractor and Ensure

Receive Concrete Pour Authorization


C.P.A. Request from the contractor.

Check all items of C.P.A. as per


requirements of specifications and
Drawings and approve.

Mixing, Transportation and Pouring


of Concrete. Check by Physical
Inspection and Test Procedure.

Compressive Strength of Concrete


Cylinders.
Check
by
Test
Procedures.

Record of all Tests made during the


period. Update Periodically.

Lab
Tech
nicia
n
Lab
Tech
nicia
n
Lab
Tech
nicia
n
Lab
Tech
nicia
n
Lab
Tech
nicia
n
Lab
Tech
nicia
n.
Lab
Tech
nicia
n.

porting
Document

Manufactu
rers
Certificate
and/or
External
Lab.
Format.
Manufactu
rers
Certificate
and/or
External
Lab.
Format.

Ref.
Section
3.7

Ref.
Section
3.7

Ref.
Section
3.7

Ref.
Section
3.7

Ref.
Section
3.7

Ref.
Section
3.7

Ref.
Section
3.7

All actions should be taken in accordance with Contract Specifications and


Contractors work methodology as approved by the Engineer.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

2.4
2.4.1

STONE PITCHING & STONE APRON


Objective

Objective of this Section is to provide the scope of applicability of the

recommended guidelines, sequential inspection procedures and other relevant


information to the Contractors field staff, for their guidance in performing quality
assurance of stone pitching and stone apron to the Permanent Work, being
executed by the Contractor.
2.4.2

Applicability

This Section covers the placing of stone pitching and stone apron at the

specified locations as shown on the drawings. The recommended guidelines can


also be used for similar works elsewhere in the project, as directed by the
Engineer.
2.4.3

Construction Equipment

The equipment specified in the contract Specifications are only to provide

guideline to assist the Contractor in the selection of proper equipment. The


Resident Engineer must leave the final selection to the contractor. The Contractor
may deploy the following equipment.

2.4.4

Excavators

Dump Trucks

Dozer and Rippers

Water Bowser

Front End Loaders

Dewatering arrangements

Inspection

For Quality Assurance (QA) of Construction activities the Contractors Staff


shall proceed in accordance with CKL-1.4 Checklist for Stone Pitching &
Stone Apron.

Base Filter Layer under Stone Pitching shall consist of well graded material
as specified in BOQ and shown on the Drawings.

The Stones individually shall weigh between 40-120 lbs with 80% shall be 80
lbs or larger and not more than 5% shall weigh less than 40 lbs.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

All interstices in Stone Pitching/Apron shall be well filled with rock Spalls. The
rock Spall shall be rock fragments size between 2 inches and 4 inches.

The surface over which the base filter is to be placed shall be trimmed to the
proper lines and grades and shall be moistened with water and tamped or
rolled with suitable tools or equipment for the purpose of forming a firm
foundation. Wherever over-excavation occurs it shall be backfilled with
specially compacted fill.

The base filter layer shall be placed to a uniform thickness and finished to
reasonably smooth and even surface.

Stone used in the Stone Pitching/Apron shall be clean rough quarry stone and
shall be essentially free from dust, clay, vegetative matter and other
deleterious materials. The stone shall be hard, tough, durable, dense,
resistant to the action of water and air, and suitable in all respects for the
purpose intended. The stones shall be hand packed and placed and bedded
in such a manner that the completed stone pitching is stable and without
tendency to slide.

Construction of stone pitching shall commence at the lowest part of each


structure or section of a structure or canal and continue progressively upward.
The stones, largest of which shall be used at the bottom, shall be well bedded
on a layer of graded Granular Material. In general the size of the stone used
shall have its major dimension the depth of the specified pitching.

Large open spaces between the stone shall be avoided.

Stone shall be placed so as not to project above neat lines shown on the
drawings.

2.4.5

Quality of Stone

While performing control over procurement and placement of stone and filter material,
the following characteristics of stone and filter material from the specifications must be
observed.

Stone for pitching/Apron should be dense, sound, angular and resistant to


abrasion.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

The loss in Los Angles Abrasion Test for large size Aggregates
(ASTM-C535-96) should not exceed 10% by weight at 200 revolutions or 40%
by weight at 1000 revolutions.

The loss in Los Angles Test for small size Aggregates (ASTM-C131-96)
should not exceed 10% by weight at 100 revolutions or 40% by weight at 500
revolutions.

The Specific Gravity of stone (Saturated Surface Dry basis) shall be more
than 2.60.

2.4.6

Test Procedures Frequency and Facilities


The recommended test procedures their frequency and required facilities for an
effective quality control of stone pitching and stone apron are presented in
QAP/Stone/Test Procedures.
CKL 1.4 CHECKLIST FOR STONE PITCHING AND STONE APRON

Sr.

Issue

Action by

No.

Document

1.

Study and Analyse


Method Statement.

2.

Confirm by Survey Control Levels of


TBMs established by the Contractor.

3.

Record/Reporting

Contractors

Check by Survey Control and


Dimensional Inspection Complete
setting out/layout as per drawings and
specifications.

Ref. Section 3.7

-A. R.E. Rep.

4.

Check by visual Inspection and


Survey Control location and level of
level pegs. These should be clear of
working area.

5.

Check by Physical Inspection and


Test Procedures. The Quality of Base
Filter Material, Pitching/Apron Stone
and Rock Spalls.

Cont. site
engineer

Test Results on
External Lab.
Format or Field
Lab.

6.

The material of Base Filter, Stone and


Rock Spall should be obtained from
approved source.

Cont. site
engineer

Ref. Section 3.7

7.

Ensure

Cont. site

Ref. Section 3.7

by

Physical

Inspection

- Contractors
Surveyor

Ref. Section 3.7

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

8.

Placement of stone pitching and


Stone Apron.

engineer

Update Periodically Records of all


Tests made during the time period.

Cont. site
engineer

Test Record File

All actions should be taken in accordance with Part Two, Contract Specifications and
Contractors work methodology as approved by the Engineer.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

2.5
2.5.1

BRICKWORK
Objective

Objective of this Section is to provide the recommended guidelines, sequential


inspection procedures and other relevant information to the field staff of the consultants,
for their guidance in performing Quality Assurance of Brickworks for Structures pertaining
to the Permanent Works, being executed by the Contractor.
2.5.2

Applicability

This Section covers the construction of Brickworks for brick masonry and brick lining for
various Structures, being executed by the Contractor.
2.5.3

Construction Equipment

The Resident Engineer must leave the selection of construction equipment to the
Contractor.
2.5.4

The Consultants Action

The Consultants field staff will take appropriate action as recommended in the checklist
CKL-1.5 Checklist for Brickwork.
2.5.5

Quality of Bricks

The bricks should be regular, uniform in shape and size.

Bricks over-burnt, under burnt and irregular should not be used.

All bricks in oven-dried condition should not absorb more than one sixth of
its weight when soaked for one hour in water at 70 0 F to 800 F and should
show no efflorescence on subsequent drying.

The average compressive strength of five (5) representative bricks should


not be less than 2,000 lbs/in2 when tested in accordance with ASTM.C-67.

Each finished brick should be of standard size (9 x 4.5 x 3) first class


and weigh between seven (7) and nine (9) pounds.

All bricks should have a frog. 0.25deep on upper face.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

2.5.6

Each brick for lining should have standard size (9 x 4.5 x 3) first class.

Mortar Composition

Mortar for all brickwork should have mix ratio as specified in BOQ and sufficient water to
produce the proper consistency.
2.5.7

Mortar Sand

Mortar Sand should be as per specifications of sand for concrete works.


2.5.8

Water

The water used for preparation of mortar should be free from objectionable quantities of
silt, organic matter alkali, salts and other impurities.

CKL 1.5 CHECKLIST FOR BRICKWORK


Sr.
No.

Issues

1.

Study and Analyse. Contractors Method


Statement.

2.

Check
by Survey Control
and
Dimensional
Inspection,
complete
setting out/layout as per drawings.

3.

Check by Physical Inspection and


Survey Control, location and level of
level pegs. These should be clear of
working area.

Action by

Record/Reporting
Document
Ref. Section 3.7

- A.R.E. Rep.

FR-02 for
comments

- Contractors
Surveyor

4.

Physically inspect Sand, Cement and


Bricks and confirm adherence to the
specifications by Test Procedure.

External Lab or
Field Lab Format

5.

Discuss with and Ensure, deployment of


proper equipment as described in the
Work Methodology submitted by the
Contractor.

A.R.E./Site
Inspector/ Cont.
site engineer

6.

Check all items as per requirements of


specifications and drawings.

A.R.E./Site
Inspector/ Cont.
site engineer

7.

Update Periodically, records of all Tests

A.R.E./Field Lab.

Ref. Section 3.7

Test Record Files

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

made during the period.


All actions should be taken in accordance with Contract Specifications and Contractors
Work Methodology as approved by the Engineer.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

QUALITY CONTROL PLAN

3.1

PREFACE

SINOHYDRO-NEL Joint Venture is, in particular, responsible for the Quality Control of
the Works as per Contract Specifications. Consultants supervision and surveillance does
not relieve the Contractor of his contractual obligations. The basic purpose of this plan is
to ensure that the Quality Control System is in place and performing to the requirements
of Contract documents, during the construction period.
The quality requirements are based on technical specifications as per contract
documents for Rehabilitation and Upgrading of Pakpattan Canal, Khadir Branch and
Pakpattan Islam Link. Maximum efforts have been exerted in making QCP (Quality
Control Plan) an acceptable and tangible document for all levels of execution and
supervisory staff and novice to experience.
The Contract Documents are the basis for this Plan, therefore, where an ambiguity is
detected between the procedures and requirements of QCP and content of Contract
Documents then the latter takes the precedence.
3.2

DOCUMENT CONTROL

3.2.1 Purpose
The purpose of site document and data control is to ensure that all the quality system
documents are properly numbered reviewed and approved prior to issue and
communication. They are available at the appropriate locations and changes to them are
properly documented, authorized and indicated.
3.2.2 Responsibility
Document Controller at site is responsible for the control of all data and documents.
Document Controller is responsible for following;

3.2.3

Responsible for all incoming and outgoing correspondence, distribution and as


filing per SOP.
Responsible for all incoming drawings and custodian of the original copy,
distributing the controlled copies to the concerned persons.
Responsible for getting the documents/drawings from the site.
Responsible for keeping safe custody of all contractual documents.
Responsible for keeping all permanent / final documents till handing over to
Consultant or Clients.
Responsible for maintaining the document register.
He shall establish the filing system accordingly. This may be amended from time
to time to current requirement.
Incoming & Outgoing Correspondence:

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

All Incoming correspondence from Consultant & client shall be separately filed
and issue the copies to the concerned persons. A separate register / electronic file shall
be maintained. All incoming correspondence from sub-contractor / supplier shall be filed
separately in different folder for each & necessary action. All outgoing correspondence to
Consultant & Clients shall have complete reference.
3.2.4

Contractual Documents
All original contract documents shall be in the custody of Head office in Lahore. A
copy shall be available at site for reference.
3.2.5 Internal Distribution
As soon as information received from the Consultant or Client, Project Manager shall
mark the distribution as required for necessary action / information; if the information
needs to be passed to subcontractor it shall be forwarded with a copy along with a
covering letter to subcontractor / supplier for their action.
3.2.6 Traceability
All documents shall be filed in a systematic / functional way marking index, contents of
the file, project so as to trace the required document. A master index shall be maintained
by the Document controller.
3.2.7 Confidentiality of Documents
All documents shall be controlled by document controller only and shall be kept in a
separate room with lock and key facility so that no unauthorized personnel can access to
document room.

3.3

PROCUREMENT CONTROL

3.3.1 Purpose
To ensure that procurement / purchasing activity at site conforms to SINOHYDRO-NEL
JOINT VENTURE procedures and agreed/specified requirements.
3.3.2 Scope
This procedure applies to Supplier evaluation & SINOHYDRO-NEL JOINT VENTURE
action, procurement of products, documents and verification of purchased products.
3.3.3 Responsibilities
The In-charge Procurement at Site is responsible for the following:

Sourcing and recommendation of suppliers for construction materials.

Maintaining complete record of supplied items, materials, goods, components or


services etc.

Developing and maintaining an approved vendor/ supplier list.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Ensuring timely supply of materials in the right quantity and of the


specified/agreed quality/standard.

Co-ordination of Procurement functions with Site QA/QC for in-coming


inspections.
Maintaining Purchase Requisitions, Purchase Orders, Delivery Challans, Material
Receiving & Acceptance Reports and Invoices of Suppliers.

3.3.4 Types & Classification of Procurement


Major procurement at site will constitute the following type of Construction items
according to the scope of the project;

Civil

Mechanical

Electrical

Services of sub-contractors

3.3.5

Material Procurement & Source Approval

In order to get the desired progress, Procurement In-charge is responsible for managing
procurement activities. The SINOHYDRO-NEL JOINT VENTURE will obtain source
approval; submittals will include the name and address of all manufacturers and suppliers,
test results showing complete compliance with the Specifications and specified Standards,
the date of manufacture and storage condition, shelf life if appropriate. In addition, the
Contractor shall provide representative samples of the materials of sufficient size such that
the Engineer may perform all specific tests. Once source approval has been granted by
the Engineer all deliveries of the material to the site must in turn be submitted for approval
accompanied by all relevant test reports to show full compliance of the material with the
Specifications. Where the required tests cannot be performed at the site laboratory, then
the Contractor shall arrange for independent testing at a laboratory approved by the
Engineer, to be performed to show that the material complies with the Specifications. Cost
of such testing shall not be reimbursed.
3.3.6

Services of Sub-Contractors

SINOHYDRO-NEL JOINT VENTURE will endeavor to perform all the major works by his
own team but few specialized jobs, like specialized Mechanical gates etc. are planned to
be awarded to the specialized sub-contractor after the prior approval from the Client /
Engineer. SINOHYDRO-NEL JOINT VENTURE will be fully responsible for any part of
the works performed by him or his subcontractor(s) and for the acts and omission of the
subcontractor.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

3.4

CONSTRUCTION MATERIAL CONTROL

3.4.1 Purpose
To establish and maintain a unique identification and record system to trace the history,
location, quality and application of the material. To identify the material during all stages
of construction through the drawings & specifications and processes.
3.4.2 Scope
This procedure is applied for this project, including project management and project Site.
3.4.3 Responsibilities
Store in-charge & Store Keeper at site are responsible to ensure that construction
material records are maintained and procedures followed to establish a unique
identification and traceability for each material.
3.4.4 Procedures
Site Stores is to ensure that all items are properly identified with their unique
identification names and codes. The Store in-charge is responsible to ensure that all
quality records and documentation used for the transaction of materials include their
proper identification.
The Construction Manager(s) at site are responsible to ensure that the following
identification and traceability procedures are followed:
The Material on the project Site is to be marked with a unique Identification method for
its proper recognition, identification of location, product and materials by reference to the
drawings and specifications. The Construction Managers along with his project team is
responsible to identify the need & methods of these unique identifications.
The work done during the tenure of the Project is to be appropriately documented to
ensure that all inter-related activities, material and products are traceable to each other
and their sources.
3.5

PROJECT PROCESSES

3.5.1 Purpose
To provide a system for effective Project planning, Execution and Control of various
project processes during construction phase of the project.
3.5.2 Scope
This procedure is applicable to the following processes at site.
a) Project Quality Management.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Project Planning.

Resource Planning (Man, Machine & Materials).

Organization.

Monitoring and Control.


b) Project Mobilization.
c) Execution.

Methods.

Specifications.

Process Validation.

Inspection & Testing.


d) Safety, Health and Environment.
e) Maintenance of Equipment & Tools.
3.5.3 Responsibilities
The Project Manager is responsible to ensure that this procedure is effectively being
implemented.
3.5.4 Project Quality Management
Project Quality Management at site is to include planning, organizing, monitoring &
controlling processes. The objectives of this quality management apply to all Project
Management Processes.
Project Planning
Each contract shall have project planning for effective resource and execution
schedule planning. For that purpose detailed construction schedule plan shall be
prepared and implemented during construction phase. Project planning includes
but not limited to Work, Activity base planning, Resource planning and
establishment of progress review system for proper implementation.
Resource Planning
Overall Resource Planning for the project shall be done for Manpower, Machines
and Materials in accordance with each applicable contract. Project resource
planning shall be done for the project by breaking the phases & processes into
sub-processes.
Project Organization
The site will plan its organization to undertake project assignments in accordance
with the Project Resource and Execution plan. This Project organization is the
owner of all processes at site.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Project Monitoring & Control


To effectively monitor and control the project specifications and schedule, the
following reports are to be generated at indicated intervals for reviewing and
necessary action:
Daily Progress Report
Weekly Progress Report
Monthly Progress Report

3.5.5 Project Mobilization


The Project Manager is responsible along with his project team to define and develop a
project mobilization plan.
The Mobilization plan will include the following:
1. Mobilization of Temporary Facilities
2. Manpower
3. Equipment & Machines
4. Facility Layout
3.5.6

Execution
Methods & Specifications
The client as a basis has provided standard execution procedures and
specifications for preparation of work methodology. Methodology is to be
prepared by the Planning Section in each discipline in consultation with field staff.
The Methodology is to be prepared for each execution process, reviewed by
Project Manager. During the start of every project activity, Consultant validated
and approved Methods are to be made part of the Quality Control Plan (QCP).
Inspection and Testing
Inspection and Testing shall to be incorporated in the methods, which shall be
applied after validation by the consultant. The Site execution is responsible to
proceed according to the Method while QA/QC team is responsible to apply
during each process. Approved third-party inspection and testing facilities may be
utilized if required. The procedure and applicable records are explained in the
section dealing with Inspection and testing.
Process Validation
In order to ensure appropriate level of conformance to the process validation, the
site QA/QC team shall plan and execute internal audits of the site from time to
time.

3.5.7

Safety, Health and Environment

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Environmental Management Plan given by Client in Contract Document (Vol-2) will be


used as Safety, Health and Environment Manual. All the preventive measures during
construction phase will be taken as per EMP. HSE Manager is responsible for all Health,
Safety, Security and an Environmental issue arises during the execution of the project.
To effectively monitor and control the projects Health, Safety & Environmental issues,
following plans & reports are to be generated for reviewing and necessary action:

Site Specific Environmental Management Plan


Daily, Weekly & Monthly HSE Performance Reports
Site Safety Inspection Reports.
Internal Audit Reports.
Accident / Incident Reports
Social Compliant Reports
Water, Air Quality & Noise Level reports as per EMP.
Tool Box Talk / Training Records.
Dispensary / Treatment Record.
Other reports, Records and Plans as per approved EMP.

3.5.8 Maintenance of Equipment/ Tools


To control the process for maintenance of Machinery, Tools and Equipment, Machinery
Supervisor is responsible to maintain a complete schedule of preventive and breakdown
maintenance of all project vehicles, machinery, tools and equipment.
3.6

CALIBRATION OF VARIOUS DEVICES / EQUIPMENT

3.6.1 Purpose
To ensure a system for calibration and maintenance of Inspection, Measuring and
Testing Equipment (IMTE) at Site.
3.6.2

Scope

This system applies to all activities where IMTEs are used for inspection and testing of
parameters that directly effect the quality.
3.6.3 Responsibilities
QA/QC Manager is responsible for ensuring that the Calibration of all Inspection,
Measuring and Testing Equipment (IMTE).
3.6.4 Procedure
Standard procedures will be followed to assure that test and measuring devices used to
test, or accept materials or components are calibrated at specified intervals to maintain
the proper accuracy. Devices used shall be of a proper range, type and sensitivity to
reliably measure the parameters being evaluated. The calibration of such devices shall
be documented and shall be performed using certified measurement standards and
submitted to the Engineer for approval. All IMTE are to be maintained at site in a
calibrated condition. In case an IMTE is found to be out of calibration, it is to be

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

segregated from the others and put out of service in the Site store in an area marked
OUT OF CALIBRATION.
3.7

TEST PROGRAMME

3.7.1 QC Testing Facilities


The SINOHYDRO-NEL Joint Venture shall ensure that proper representative samples
are taken from each lot and sub-lot, identify the tests and analysis required, and ensures
that the tests and analyses conducted are in accordance with internationally accepted
procedures and standards.
As a part of the construction materials QC programme, the SINOHYDRO-NEL Joint
Venture shall set up a field laboratory at his own cost. The field laboratory shall be in full
working order suitably equipped and staffed to carry out all routine sampling and testing
necessary for successful and timely completion of the works according to the
specifications.

3.7.2 Tests to be performed at site


These tests are field specific and include the following:
a)

Soil

Auger sampling, ASTM D-1452

Plasticity Index test, ASTM D-4318

Grain size analysis, ASTM D-422

Moisture density relationship, ASTM D-698 and 1557

Visual identification classification, ASTM D-2488

Classification of soils for engineering purposes, ASTM D-2487

Max. and Min. index densities, ASTM D-4253 and ASTM D-4254

Proctor needle penetration, ASTM D-1558

Moisture content of soils, ASTM D-2216

In-place density, ASTM D-1556, ASTM D-2167 and ASTM D-2937

Specific gravity, ASTM D-854

California Bearing Ratio, CBR AASHTO T-193 or ASTM D-1883

Water Soluble Chloride (CL), B.S. 1377

Water Soluble Sulfate (SO3) B.S. 1377

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

b)

c)

Aggregates and Concrete

Sampling of aggregates, ASTM D-75

Sampling of fresh concrete, ASTM C-172

Sieve analysis of aggregates, ASTM C-136

Specific gravity and absorption of aggregates, ASTM C-127 and ASTM C128

Slump of concrete, ASTM C-143

Unit weight of fresh concrete, ASTM C-138

Unit weight of aggregates, ASTM C-29

Making and curing of concrete cylinders, ASTM C-31

Compressive strength of concrete cylinder ASTMC39

Water Soluble Chloride (Cl) ASTM C1812 or BS 812

Water Soluble Sulfates (SO3) BS 1377

Stone

Los Angeles Abrasion Test for Stone.

Tests to be performed at Field Laboratory


The tests to be performed at Contractors Field Laboratory include the following but not
limited to these:

Soil classification Tests

Compaction Tests

Gradation Analysis of Aggregates as required by R.E.

7 and 28 days compressive Strength Tests on concrete cylinders.

Unit Weight of aggregates.

Fresh Density of concrete.

Absorption and Compressive Strength of bricks.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Specific Gravity and Absorption of coarse and fine aggregates.

Los Angeles Abrasion Test for Coarse Aggregate

Soundness of Aggregate

Test to be performed at external laboratories/ Consultants laboratory


These tests can only be performed in specified off-site laboratories and include tests on
reinforcing steel, cement, abrasion, petrography, soundness of concrete aggregates,
water stop and any other tests required during any problem or dispute.

TESTING ARRANGEMENTS/EQUIPMENTS
3.7.3

Testing at Construction Site

The Contractor for an individual contract package shall be responsible for providing the
equipment and carrying out these tests in accordance with the Technical Specifications
under the direct supervision and guidance of the Consultants supervision staff.
The contractor is required to provide and readily make available at construction site the
following equipment,
Earthwork:

Sand - Cone Density Apparatus, complete with base plate and sand bottle.

Density Core Cutter 4 dia, complete with collar and hammer.

Speedy Moisture Tester capacity 20.0 gm. Moisture range 0 20% complete with
electronic balance and plastic carrying case.

Balance Triple Beam 2610 gm capacity with readability of 0.10 gm.

Balance 30 Kgs capacity with readability 1.0 gm.

Drying Oven capacity 108 Litres.

Concrete Work:

Cylinder moulds for concrete 6 dia. Complete with tamping rod (5/8 in dia 20
long) and mallet.

Slump Test Equipment complete with tamping rod 5/8 dia and 24 long.

Curing Tanks These shall be constructed close to the construction site for
storing concrete cylinders till their transportation to the Laboratory for testing.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

A reliable compression machine approved by the Consultants Material Engineer.

Thermometers to check fresh concrete temperature.

Note:

The Contractor shall ensure that sufficient No. of the above equipment is
available at site to satisfy the testing requirements of the quantum of work.

Computers with printers should be provided in laboratory.

3.7.4

3.7.5

Testing in the Engineers Field Laboratory


A material testing laboratory established at site should be equipped and
adequately staffed to carry out the field laboratory tests as per requirements.

This Field Laboratory, established by the contractor and supervised by the


Consultants Quality Control / Assurance staff is to carry out the required tests
and maintain a systematic and retrievable record. Test record should be
computerized.

All Quality Control/Quality Assurance tests specified to be performed in the


field laboratory shall be carried at the designated Field Laboratory at site.
(Individual arrangements by the contractors for this category of tests shall not
be acceptable.

The Contractors shall be responsible for providing and transporting the test
specimens to the laboratory under the guidance and supervision of the
Consultants Resident Engineer.

The contractors shall bear the cost of these tests as per rate list available at
any Field or external Laboratory specified by the Engineer.

Testing from External Laboratory

The Quality Control tests to be carried out from an external laboratory defined in are
recommended to be carried out at laboratories mentioned below or as directed by the
Engineer. The cost of transportation and testing charges shall be the Contractors
responsibility. Following or any laboratory specified by the Engineer shall be used for
external testing;

Central Material Testing Laboratory (CMTL) WAPDA Lahore.

University of Engineering & Technology Lahore.

Punjab University (Environment and Soil College).

PCSIR Laboratories Lahore and Karachi.

Cement Research & Development institute Kot Lakhpat, Lahore.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Pakistan Standard and Quality Control authority. In PITAC Compound, Lahore.

3.7.6 TESTING REQUIREMENTS


The test procedures and the test frequencies for the various construction works have
been summarized in the following tables.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Material

Test

Designation

Testing Frequency

SOIL
Grain Size Analysis

ASTM D-422

1 for 30,000 cft

Liquid Limit

ASTM D-4318

1 for 50,000 cft

Plastic Limit

ASTM D-4318

1 for 50,000 cft

Shrinkage Limit

ASTM D-427

1 for 50,000 cft

Moisture
Relationship

Density ASTM D-698

1 for 50,000 cft

Moisture
Relationship

Density ASTM D-1557

1 for 50,000 cft

Field
Density
Embankment

for

ASTM D-1556

1 for 20,000 cft

Field Density for Backfill

ASTM D-1556

1 for 5,000 cft

Moisture Content

ASTM D-566 or ASTM D2216

1 for 7,500 cft (min. 2


for each layer)

Specific Gravity

ASTM D-854

Min. 3 per source or


type of material or as
directed
by
the
Engineer

Relative dry density

ASTM D-4253 & ASTM D4254

1 for 10,000 cft or as


required
by
the
Engineer

CBR

AASHTO T193

As required

Sieve Analysis

ASTM C-136

1 for 7,000 cft

Material Passing # 200


Sieve

ASTM C-117

1 for 7,000 cft

Unit Weight

ASTM C-29

1 for 17,500 cft

ASTM C-127 & ASTM C128

1 for 17,500 cft

Moisture Content

ASTM C-566

1 for 17,500 cft

Soundness

ASTM C-88

1 for 70,000 cft

COARSE AGGREGATE

Specific
Gravity
Absorption

and

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Los Angles Abrasion

ASTM C-131

1 for 70,000 cft

ASTM C-142

1 for 70,000 cft

Petrographic Analysis

ASTM C-295

3 for each source

Lightweight Particles

ASTM C-123

1 for 70,000 cft

Water Soluble (Cl)

ASTM C-1812, or BS 812

Water Soluble (SO3)

BS 1377

1 per lot / source or


as directed by the
Engineer

ASTM C-136

1 for 5,000 cft

ASTM C-117

1 for 5,000 cft

ASTM C-29

1 for 10,000 cft

ASTM C-128

1 for 10,000 cft

Moisture Content

ASTM C-566

1 for 10,000 cft

Soundness

ASTM C-88

1 for 50,000 cft

Clay Lumps
Particles

&

Friable

FINE AGGREGATE
Sieve Analysis
Material
Sieve

Passing

#200

Unit Weight
Specific
Gravity
Absorption

Material

and

Test

Designation

Testing Frequency

ASTM C-142

1 for 35,000 cft

Sand Equivalent

ASTM C-2419

1 for 35,000 cft

Organic Impurities

ASTM C-40

5 per each source

Lightweight Particles

ASTM C-123

1 for 50,000 cft

Petrographic Analysis

ASTM C-295

3 for each source

Water Soluble at

ASTM C-1812, or BS
812

1 per lot / source or


as directed by the
Engineer

Clay Lumps
Particles

&

Water Soluble SO3

Friable

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

BS 1377
CEMENT
Setting Time

ASTM C-191

1 per lot or 2500


bags

Mortar Strength

ASTM C-109

1 per lot or 2500


bags

ASTM C-114

As required

Size and weight

ASTM 615

As required

Elongation

ASTM 615

As required

Bending

ASTM 615

As required

Tensile Strength

ASTM 615

As required

ASTM 615

As required

Complete
Analysis

Chemical

REINFORCEMENT

Complete
Analysis

Chemical

Complete
Analysis

Chemical

WATER

CONCRET
E

Making
and
concrete specimen

curing

Once
month/Source
ASTM C-31

As required

Compressive Strength

ASTM C-39

1 for 2,000 cft

Slump

ASTM C-143

1 for 2,000 cft

Air Content

ASTM C-231

1 for 2,000 cft

Temperature
Fresh Density

1 for 1,000 cft


ASTM C-138

1 for 5,000 cft

Air Entraining

ASTM C-260

As required by the
Engr.

Chemical Admixtures for


Concrete

ASTM C-494

As required by the
Engr.

Curing Compound

ASTM C-309

As required by the
Engr.

ADMIXTURES

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

OTHERS
Joint Filler

ASTM D 1752-84

As required by the
Engr.

Joint Sealant

ASTM C 920-98

As required by the
Engr.

Waterstop

US Federal Test

As required by the
Engr.

Method
No.601

3.7.7

Standard

QC Test Results

All QC tests results shall be submitted to the Engineer for his review and acceptance. The
test results must show full compliance with the Specifications, in order for the works to be
approved.

3.8

a)

Soil reports showing locations, material source, material type, density, moisture
content, density-moisture content relationship, degree of compaction (RC) and
relative density where applicable.

b)

Concrete reports showing source of all constituents, testing of source material,


date of manufacture, testing of material after processing, including
determination of moisture content of aggregates and testing manufactured
concrete, concrete slump, compressive strength, temperature during placement
etc. Certification of all cement supplies, and storage records.

c)

Aggregates reports for filters, base course, showing source of material, test
results showing compliance with the specification and placing location.

d)

Ancillary reports for materials such as steel, pre-stressing strand, jointing


compound, sealant etc., showing name of source, date of manufacturers shelf
life, storage conditions, place of storage, test results showing compliance with
the specification and placing records.
QUALITY RECORDS

Purpose
To provide a system for identification, collection, indexing, filing, storage, maintenance
and disposition of quality records at Site.
Scope

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Documents consist of recording formats, which furnish objective evidence of the extent
of the fulfillment of the requirements for quality. Quality Records to be used at Site
consist of Consultant / Client specified or site specified formats.
Responsibilities
QA/QC team at site is responsible to ensure that quality records are distributed,
maintained and controlled at each owner department/section through the project
execution. QA/QC team is responsible to generate the filled formats of quality records.
They will ensure their maintenance and distribution.
Procedure
Identification

Records are to be recorded on specified Performas as given in Table 3.1.

Records are to be identifiable to the product, person or event to which they


pertain.

Records are to be dated, and signed by the person who establishes the record.

Records are to be indexed and grouped, where necessary, to facilitate their


retrieval.
Records are to be signed by the Engineer Representative for validation / approval
if required.

Retention of Records
The retention period of records is to be established for the periods during which the
record may be required for study or verification in accordance with the contract.
Storage
Records are to be stored in files that are to be properly numbered and indexed for easy
retrieval and to avoid damage. Cabinets containing records are properly labeled to
display their contents.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Laboratory Record/Reporting Documents


Table: 3.1

Laboratory Record/Reporting Documents


( Field Laboratory )

Document No.

Document Description
SOIL

LR-01

Particle Size Analysis of Soil

LR-02

Moisture Content of Soils

LR-03

Liquid Limit, Plastic Limit and Plasticity Index of Soils

LR-04

Specific Gravity of Fine Grained Soil Particles

LR-05

Laboratory Compaction characteristics of soils

LR-06

Field Density & Degree Of Compaction of Non cohesive soils

LR-07

Field Density & Degree Of Compaction of cohesive soils

LR-08

Summary of Compaction Control Test for Cohesive soils

LR-09

Summary of Compaction Control Test for Cohesion less soils

LR-10

Sieve Analysis ( Hydrometer Method) and its Graph

LR-11

Field Density Test Core Cutter Method


CONCRETE

LR-12

Particle Size Distribution of Concrete Aggregates

LR-13

Concrete Compressive Strength

LR-14

Request for concrete pour Authorization

LR-15

Flakiness and Elongation index

LR-16

Concrete Cylinders/Cubes Casting and Delivery Report

LR-17

Summary of Cylinders/Cubes Test Result

LR-18

Concrete Mix Design

LR-19

Concrete Delivery Slip

LR-20

Concrete Delivery Record Summary

LR-21

Concrete Pouring Record Summary

LR-22

Unit Weight Of Aggregates

LR-23

Specific Gravity of Coarse Aggregates

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

LR-24

Specific Gravity of Fine Aggregates

LR-25

Blend Of Aggregates & sand

LR-26

Moisture Content of Aggregates

LR-27

Unit Weight and Yield of Fresh Concrete

LR-28

Sand Equivalent

LR-29

Sulphate Soundness

LR-30

Density of Bentonitic Slurries

LR-31

Concrete Pour Authorization

LR-32

Tendon Stressing Record /Post Tensioned Concrete

LR-33

Clay Lumps and Friable Particles

LR-34

Concrete Mix Design Summary

LR-35

Concrete Batch Plant Calibration

LR-36

Curing Tank Record

LR-37

Test Report Summary of Coarse Aggregates

LR-38

Test Report Summary of Fine Aggregates

LR-39

Sieve Analysis Passing # 200 Sieve

Misc.
LR-40

Weather Record

LR-41

Monthly Lab Test Summary

LR-42

Stone Pitching

LR-43

Bricks Tests Report

LR-44

Bricks Testing Summary

LR-45

Speedy Calibration and its Graph

LR-46

Cone Calibration and Unit Weight

LR-47

Daily Lab Progress Report

LR-48

Los Angles Abrasion Test

LR-49

Material Approval Submittal

LS-01

Survey Level Sheet

BB-01

Format for Bar Bending Schedule

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

FR-01

Check Request

FR-02
Field Note
Note: FR = Field Record, LS = Level Sheet, BB = Bar Bending Schedule
Note: All above listed documents are given in ANNEXURE B.
3.9

TRAINING

3.9.1 PURPOSE
To establish a system for determining the need of staffs training, providing training and
maintain training records at site.
3.9.2 SCOPE
This procedure applies to all training programs provided by SINOHYDRO-NEL JOINT
VENTURE at site.
3.9.3 RESPONSIBILITIES
PM and SM are responsible for identifying and recommending employees after
assessing the training needs of their staff.
Manager Admin is responsible for the following:

Arranging training of recommended Site employees.

Keeping record of external training of Site employees.

Arrange orientation on quality assurance and maintaining relevant record for the
site.
Arrange orientation and maintain record at Site for new appointees/transferred
personnel.
Maintaining the record for internal/external training of Project Site personnel.

3.9.4 PROCEDURE
Orientation
Arrangements for orientation of new appointees/transferees are to be made by the
Manager Admin at site in the following areas;

General rules and regulation of the company/Site rules & regulations.

Project Orientation.

Companys Quality Policy and System.

Departmental Operations and Job descriptions.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Safety policy & rules.

Training record of above-mentioned orientation is to be maintained.


3.9.5 Training Needs
It is the responsibility of the PM and Site Manager to identify training needs for their staff.
They are to determine training needs by observing the following;

Skill and Work Know-how and practices of the employees.

Nonconformities detected in the process or internal quality audits.

Any other non-conformity in construction methodology & procedures may imply a


training need.

The needs, thus identified are to be forwarded to the Manager Admin.


The request is to be evaluated and treated in accordance with the review, feasibility and
importance. Appropriate arrangements are to be made if approved.
3.9.6

TRAINING RECORD

Internal
Based on the training course attended by the employee training record is to be updated.
External
After successful completion of external training the employee is to submit a copy of the
training certificate to Manager Admin for record in his personal file.
3.10 INTERNAL QUALITY AUDITS
3.10.1 Purpose
To provide a system for conducting Internal Quality Audits and determine whether quality
of activities and related results are complying with planned arrangements and whether
these arrangements are implemented effectively.
3.10.2 Scope
This procedure is applicable to all Site activities falling within the quality system.
3.10.3 Responsibility
Project Manager & Site Manager at Site are responsible for establishing the team, to
perform Internal Quality Audit. P.M. will be the head of the audit team. Site Manager,
Planning Engineer and Construction Managers shall be the members of Audit Team.
3.10.4 Procedure

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

To provide a procedure for conducting Internal Quality Audits and to determine whether
the site Quality Assurance activities are conforming to the system, giving the desired
results and complies with plans, quality audit process is as follows.
3.10.5 Quality audit process
Audit Program
The Audit Team Leader shall do the following:

Prepare an Audit Program listing the Manpower and its individual responsibilities

Infrastructure requirements, type and duration

Period of Audit

Relevant Notes, Checklists and Time Sheets

Working Files of Previous Audits, if any, for clearance of the outstanding matters.

Informing the Scope of Audit

Providing the QC Team with a list of requirements especially documents and


availability of personnel who may be needed including duration

Meeting with QC Team


The Team Leader of Audit Team should always ensure that his audit would not disrupt
the duties of the QC Team and his staff nor hinder the smooth operations of the
department being audited. Thus it is of utmost important that he is exible and as far as
practicable to accommodate the needs of the QC Team.
During The Audit
The Audit Team should then commence his audit systematically and in accordance with
the approved program. The Audit Team should ensure the following:

Have an opening conference with the QC Team and those involved in explaining
the scope, duration and need for documents etc. and providing explanations as
necessary

Visiting the site of the project, obtaining a brieng and getting the feel of the
works, site conditions, progress, materials, etc.

Documents or any changes to terms & conditions in standard forms or company


approved formats / procedures.

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

Clarify and obtain explanations and remedy where necessary with verbal or
written responses.

At The End of Audit


The Audit Team should have a final closing meeting with the QC Team covering all
relevant matters. The result of the discussions should be documented Instances where
the QC Team disputes the Audit Teams ndings or does not agree with his views and
recommendations should be recorded together with the QC Teams rationale and
supporting reasons Prepare a Draft Final Audit Report and send it to the Management
and other relevant persons for their review. Prepare and issue a Final Audit Report

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

ANNEXURE A
(Organogram)

Rehabilitation and Upgrading of Pakpattan Canal,


Khadir Branch and Pakpattan Islam Link
Contract: PCSBIP/ICB-01

ANNEXURE B
QA/QC Reporting Documents