DESIGN & CONSTRUCTION OF

PUTATAN WATER TREATMENT PLANT 2

TABLE OF CONTENTS
1 GENERAL.....................................................................................1

1.1 POLICY..........................................................................................1
1.2 OBJECTIVE.....................................................................................1
1.3 INTERFACE WITH QUALITY MANUAL..................................................1
1.4 INSPECTION..................................................................................2
1.5 QUALITY PROCEDURE......................................................................2
1.5.1 INSPECTION NOTIFICATION.............................................................2
1.5.2 VALIDATION OF THE NOTICE............................................................2
2 ORGANIZATIONAL CHART...........................................................2

3 DEFINITION OF DUTIES..............................................................3

3.1 QUALITY CONTROL PERSONNEL, DUTY AND ORGANIZATION................3

3.2 PROJECT MANAGER.........................................................................3
3.3 CONSTRUCTION MANAGER..............................................................4
3.4 QA/QC MANAGER............................................................................5
3.5 QA/QC ENGINEER...........................................................................5
3.6 Q/C ACTIVITIES.............................................................................6
3.7 ORGANIZATION..............................................................................7
4 DOCUMENT CONTROL..................................................................8

4.1 GENERAL.......................................................................................8
4.2 DRAWING CONTROL PROGRAM........................................................8
4.3 PREPARATION OF AS-BUILT DRAWING..............................................8
4.4 REQUEST FOR DESIGN CHANGE.......................................................8
4.5 ESTIMATION OF SCOPE CHANGE......................................................9
5 DESIGN CONTROL AND DEVELOPMENT........................................9

6 PROCESS CONTROL.....................................................................9

6.1 METHOD STATEMENT......................................................................9

6.2 ACCOMPLISHMENT REPORTS..........................................................10
6.3 INSPECTION AND TESTING PLAN (ITP)............................................10
6.4 MONITORING AND MEASURING EQUIPMENT....................................11
6.5 TEST LABORATORIES.....................................................................12
7 INSPECTION & TESTING HOLD..................................................12
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7.1 REFERENCES................................................................................12
7.2 RESPONSIBILITIES.......................................................................12
7.3 MINIMUM TEST AND/OR INSPECTION REQUIREMENTS CIVIL WORKS
..................................................................................................13
7.4 MINIMUM TEST AND/OR INSPECTION REQUIREMENTS ELECTRO-
MECHANICAL WORKS....................................................................16
8 MATERIAL CONTROL STORAGE..................................................20

8.1 GENERAL.....................................................................................20
8.2 RECEIVING..................................................................................20
8.3 WAREHOUSING............................................................................20
8.4 STOCK CONTROL..........................................................................21
8.5 ISSUING OF MATERIALS................................................................22
8.6 DOCUMENTATION.........................................................................22
9 QUALITY RECORDS....................................................................22

9.1 LOT COMPLIANCE (INSPECTION AND TEST PLAN) RECORDS..............23

9.2 REQUEST FOR INFORMATION, VARIATION, SITE INSTRUCTIONS AND
NON-CONFORMANCE RECORDS......................................................23
9.3 DRAWINGS, SPECIFICATIONS AND SCHEDULES...............................23
9.4 CONSTRUCTION MANAGER'S OFFICE...............................................24
9.5 QUALITY CONTROL OFFICE............................................................24
10 CONFORMANCE & NON-CONFORMANCE.....................................24

10.1 CONFORMANCE REPORTS..............................................................24

10.2 NON CONFORMANCES...................................................................25
10.3 CORRECTIVE ACTION....................................................................26
10.4 PREVENTIVE ACTION.....................................................................26
11 RISK MANAGEMENT...................................................................26

11.1 IDENTIFIED QUALITY CONTROL RISKS............................................26

12 AUDIT FUNCTION......................................................................27

12.1 PURPOSE.....................................................................................27
12.2 SCOPE.........................................................................................27
12.3 RESPONSIBILITY...........................................................................27
12.4 AUDIT.........................................................................................27
13 INSPECTION CHECKLIST & LABORATORY FORMS......................30
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1 GENERAL

1.1 Policy

It is the policy of the Consortium that its project when completed, shall
comply with the contract specifications, standards, drawings applicable
local regulation and acceptable construction practices.

In the application of this policy, a continuous quality programs will be

provided to assure that applicable codes, specifications and standards
are complied upon.

Inspection and quality control program will produce appropriate records

and all operations will be subject to internal audits.

The inspection and quality control program can be supplemented to

satisfy contractual regulations or to encompass new materials and
techniques but may not under normal circumstances be de-emphasized
or unilaterally waived.

1.2 Objective

To provide products and services for the realization of a successful

project that meets the contract and project requirements to the
satisfaction of the client.

To meet all quality requirements and technical performance criteria for

the project.

To meet all commercial criteria by efficient utilization of technological,

human and material resources.

1.3 Interface with Quality Manual

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This Plan is subject to modification and adaptation to the meet the

specific project scope requirements and contract specifications. As a
secondary document to the Project Quality Manual, this Plan describes
all the significant activities for this project (for general planning
purpose) and what we intend to do for quality assurance for each of
these activities.

1.4 Inspection

Specific procedure such as inspection and test plans will be developed

and implemented to ensure that all quality aspects of the works will be
addressed.

The Consortium is expected to have and maintain a quality control

program that will ensure the work being accepted. The reports
generated in accomplishing this activity must reflect actual physical
quality checks and will be transmitted to consultants. The master file of
these forms with the appropriate signatures will be retained by the
consortium at the jobsite.

1.5 Quality Procedure

1.5.1 Inspection Notification

When Consortium is satisfied that a completed segment of the work

is ready for consultants inspection, preparation of the appropriate
documentation will be made with a request for work inspection that
defines and identifies the inspection desired.

Consultants engineers will check the work and if satisfied then only
the inspection request form will be signed. Consortium is required
to give consultants 24 hours to enable to carry out an inspection.

1.5.2 Validation of the Notice

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Consultants will determine if the requested inspection is valid, i.e.

that the work is indeed finished and properly documented.

2 ORGANIZATIONAL CHART
Please see enclosed QA/QC Organizational Chart.
The organizational chart will be revised and resubmitted in case of
any change of key personnel.

3 DEFINITION OF DUTIES

3.1 Quality Control Personnel, Duty and Organization

3.2 Project Manager

The Project Manager is responsible for promulgating the Quality Policy
and ensures that:

Major Duties
A. The day to day preparation for issue of all new or revised
procedures, work instructions and forms.
B. Ensuring all information is available for management review
meetings, and meeting reports and minutes are distributed to
relevant persons
C. Ensure that all procedures are followed by all workers,
Responsible for the successful delivery of a Project within time,
cost, safety, quality and environmental constraints
D. Provide hands-on, day-to-day Project management during the
execution phase of Projects
E. Establish Project monitoring budget (from Tender Budget),
Establishment of PMT to ensure appropriate management of
design, construction, commercial, financial, administration,
safety, quality, environment and communications
F. Establish site operational (design & construction), commercial,
financial, administration, safety, quality, environmental and
communication procedures
G. Ensure appropriate reporting both internally to the
Management Board and contractually to the Client
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H. Identify issues and prepare proposals for resolution of issues,

Tracking and reporting progress through establishment of key
performance indicators, Trend Analysis & Risk Management

3.3 Construction Manager

The responsibilities of the Construction Manager include:

A. Ensure the PMT are directed in a manner that delivers a high

level of safety, health, environmental and quality standards

B. Study Project specifications to determine appropriate

construction methods, producing and maintaining a Project
management plan

C. Evaluate construction methods and determine cost-

effectiveness of plans

D. Schedule the Project in logical steps and budget time required

to meet deadlines delivering the Project to the contract
documents on time and to budget

E. Work with the Design Manager, Commercial Manager and

Project Manager to ensure coordination

F. Confer with supervisory personnel, owners, contractors, and

design professionals to discuss and resolve matters such as
work procedures, complaints, and construction problems

G. Ensure General Contract Budget implementation and

monitoring prepare and submit budget estimates and progress
and cost tracking reports

H. Keep all required records as per company procedures and as

required within the contract

I. Determine labor requirements and dispatch workers to

construction sites

J. Inspect and review Projects to monitor compliance with building

and safety codes, and other regulations
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K. Interpret and explain plans and contract terms to

administrative staff, workers, and Clients, representing the
Client

L. Prepare contracts and negotiate revisions, changes and

additions to contractual agreements with architects,
consultants, Clients, suppliers and subcontractors

M. Plan, organize, and direct activities concerned with the

construction and maintenance of structures, facilities, and
systems

N. Investigate damage, accidents, or delays at construction sites,

to ensure that proper procedures are being carried out

O. Evaluate construction methods and determine cost-

effectiveness of plans

3.4 QA/QC Manager

On the instruction of the project manager, he is responsible for the

assurance and control of the quality for the project and will act as
liaison between consortium and consultants pertaining to the quality
control, inspection, testing and examination in order to meet the
contractual requirements, standards and specifications for the
project.

Major Duties
A. Job instruction and observance of QA/QC plan.
B. Training/testing of laborers.
C. Maintain all required reports.
D. Conduct activities relating to the quality assurance and
quality control of the work at the jobsite and laboratory.
E. Equipment maintenance.
F. Control of the construction materials.
G. Verify all completed work against drawing standard and
specification.
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H. Prepare QC program for consultants approval.

I. The systems necessary to manage and control Project

quality records.

J. Management and control of Project quality records during

the life of the Project.

K. Timely provision of specified records and data to the

Customer/ Client.

3.5 QA/QC Engineer

The QA/QC Engineers are responsible for implementing and maintaining
the Quality Management Plan, systems and procedures by:
A. Supporting a culture that focuses on a get it right first time
attitude across the entire workforce

B. Actioning and managing subcontractors to implement and

maintain quality systems and procedures as defined in this
Quality Management Plan

C. Ensuring the delivery of the output required of their functional

team is on time and to quality specification

D. Implementing consistent lot management, including engaging

in verification and approval activities as required by the
Inspection and Test Plans

E. Coordinating the development, updating and controlling

Inspection and Test Plans

F. Engaging in inspections and verification activities as required

by the Inspection and Test Plans

G. Verifying conformance prior to accepting completed works

H. Raising, investigating and reporting NCRs and implementing

remedial actions

I. Monitoring direct reports lot management and providing

technical support as required
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J. Cooperating with the CQR and the Client rep. to ensure

compliance with the quality system, including approvals for
materials and construction methods

K. Issuing Client notifications and inspections or monitoring direct

reports.

3.6 Q/C Activities

The following is a brief summary of inspection and test activities

required to ensure the quality and compliance with the
construction drawings, specification and standard.

1. Most of the activities will be performed by our quality control

group and some by subcontractor on behalf of consortium which
in case we will make sure the subcontractors will perform their
obligations in strict accordance with project technical
specifications and standards.

2. Materials received are inspected and signed by QA/QC Manager

for condition, a confirmation with the drawings and any damaged
or discrepancies will be brought to the attention of consultants
engineers.

3. Drawing interpretation and/or field problems as well as materials

problems will be dealt with by the quality control department
and supervisors, and consultants engineers will be informed.

4. Any problems which cannot be solved within consortium are

brought to the attention of consultants engineers in writing for
their actions. Problems in the field are documented and recorded
in the log book of consultants engineers and consortium.

5. Various forms will be used for testing and quality control of

construction materials will be approved by consultants
engineers before use.
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3.7 Organization

The quality control section will consist of a QA/QC Manager and

supplementary QA/QC Engineers who are key personnel assigned to
this quality control program and are responsible directly to the project
manager for all quality control activities in the field. The QA/QC
Engineer will answer only to QA/QC Manager.

The QA/QC Manager has a team of specialist working in the specific

areas of civil, piping, electrical, structural and architectural. Field
quality control reports made by each field supervisors shall be
forwarded to the quality control supervisor/engineer, QC specialists
shall check the work on basis of the reports.

If the checking shows deviations from drawings per specifications,

they shall instruct the relevant supervisors to conduct the required
corrective work, and then report it to the QA/QC Manager.

When the remedial work has been completed, the quality control
reports will be delivered to QA/QC Manager and Engineer. These
steps shall be repeated, until the work is determined to be acceptable
by the QC specialists.

4 DOCUMENT CONTROL
4.1 General
Engineering management to be executed by consulting engineers
and the consortium will assist to consultants for this project.

4.2 Drawing Control Program

The consortium engineer will control all drawings, with CAD operators
who will work full time on site.

If there will be any field changes, the project field engineer shall
review the drawing scheduling engineer shall keep all the records
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about field changes, voided changes, revised drawing and he will

prepare as built drawing and submit to consultants office through
project manager upon completion of project.

4.3 Preparation of As-Built Drawing

Field supervisor shall mark "red" the progress of their work on

drawings and/or on separate sheets, and submit then to scheduling
engineer after verification thereof from consultants field engineer.
Based on these marked drawings and sheets drawing engineer shall
prepare a consolidated as-built drawing. The consortium shall
maintain this as built drawing up to date and submit to consulting
engineers when work on the drawing is complete.

4.4 Request for Design Change

Field supervisors and/or foreman shall prepare and submit requests

for field design change to the consortium scheduler, who will make a
Request for Information. It will be forwarded to consulting engineers
for their perusal. Upon approval of the design change, copies will be
distributed to the supervisors and/or foremen who initiated the
requests for implementation, and will be sent to the main office and
site office for filing.

4.5 Estimation of Scope Change

In the event of scope change, cost engineer shall estimate the work
involved with field engineers, the results of which shall be submitted
to the project manager, the scope change work shall be processed in
accordance with contract document, change of work.

5 DESIGN CONTROL AND DEVELOPMENT

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Design management is an essential component of the Project

Delivery. The Project Design will be broken down into defined
components and will be classified according to each discipline

Process
Mechanical
Electrical and Instrumentation
Civil Works including Structural and Architectural Design

Regular review meetings will be held between the design and

construction consultant, client and contractors. Meetings will be
minuted, areas of concern noted for actions to rectify and to follow
up. Standard document turnaround times regarding submissions will
be implemented.

Design review will be a continuous process throughout the life of the

Project. Review workshops for all involved personnel will be conducted
where amendments can be done. The Design Manager will review and
comment and initiate any amendments before approval.

6 PROCESS CONTROL

6.1 Method Statement

Method statements are documents that fully describe the procedure

of the activity, plant, equipment and resources, safety and
environmental requirements and considerations, inspections and test
requirements. The purpose of the procedure is to ensure adequate
planning of the works and that personnel carrying out the work
understand the hazard and risk associated and the controls in place to
reduce exposure to injury and/or damage incidents.

Subcontractors and other vendors will be required to provide their

own management plans and procedures but in some cases may adopt
Consortiums management systems, where they will be required to
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participate in preparation of the construction procedures as part of

the consultation process.

6.2 Accomplishment Reports

Accomplishment reports should be submitted to monitor the progress of the
project, safety and health reports, procurement updates, weather condition,
manpower and equipment loading and activities within the reporting period.
Daily site report shall be submitted on the following day of report period.
Weekly accomplishment report shall be submitted every Friday, reporting the
activities from Friday of previous week to Thursday of the report week.

6.3 Inspection and Testing Plan (ITP)

ITPs will be prepared for all activities based on the applicable

specifications prior to work beginning. The QA/QC Engineer will be
responsible for developing the relevant Inspection and Test Plans for
upcoming works or if necessary amend the ITP to reflect any changes
prior to the activity. The QA/QC Manager shall ensure that all
specifications and technical requirements are properly incorporated.
ITPs will be owned, documented and checked by the QA/QC Manager.
They may also be authorized by the Project Manager.

ITPs require Client approval. Every activity must have the

corresponding ITP in place and approved by the Client before
commencement of any activity.

Checklists for inclusion of:

Witness Points and Hold Points

Inspection Points
Location (survey if required)
Test requests
Traceability i.e. underlying lots and supporting lots
Criteria for acceptance
Frequency of inspection / testing
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Sign-off for closure.

6.4 Monitoring and Measuring Equipment

Calibration and service records for monitoring and measuring

equipment will be maintained in a central asset register. Equipment
leased or rented will be hired on the basis that the owner maintains
them in a suitable condition at all times and provides evidence of this.
The asset register must contain as a minimum, the following
information (for owned and hired equipment):

Type
Description
Serial Number
Latest calibration (including certificate)
Next calibration date
Type of monitoring/measurements to be performed
Monitoring and measuring equipment will bear a tag, sticker or other
identification indicating calibration and/or verification status. Where
this is not practical, the calibration or verification status will be
traceable through the records maintained in the Asset Register.

All monitoring and measurement equipment used on the project must

be provided with a calibration record and must be verified before use
on site and re-calibrated as established by the manufacturer
conditions. Checks

The service and calibration will be performed by either the

manufacturer or by an organization qualified to calibrate the
instruments.

6.5 Test Laboratories

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All measuring and testing required by specifications or verification will

be made using 3rd party organizations recognized by the Client or
other governing bodies such as DENR and DPWH.

7 INSPECTION & TESTING HOLD

7.1 References

Standards Specification for Road & Bridges DPWH 2004

AASHTO - American Association of State Highway and
Transportation Officials
ISO - The International Organization for Standardization
AWWA - American Water Works Association
ASTM - American Society of Mechanical Engineers
ASME - American Society for Testing and Materials
ANSI - American National Standards Institute
PEC - Philippine Electrical Code
NEC National Electric Code
IEEE Institute of Electrical and Electronics Engineers
NEMA - National Electrical Manufacturers Association
Project Technical Specifications

7.2 Responsibilities

The requirements of this program are implemented by:

The assigned QC personnel (civil field engineer) who shall perform

periodic inspection and/or surveillance of works and material testing
coordination as defined by this program and shall complete or
monitor the specified documentation.

The material testing personnel who shall performed material testing

each work as required. This shall be under the direction of an
assigned QC personnel (engineer) for performance and
documentation compatible with this program.
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7.3 Minimum Test and/or Inspection Requirements Civil

Works
Below is the schedule of minimum test and/or inspection
requirements for each construction materials prior, during and/or
after incorporation of them to works.

7.3.1 Embankment and Sub-Grade Preparation

For every 1500 cu.m. or fraction thereof:
Quality Test:
One (1) Grading Test ASTM C136
One (1) Plasticity Test (LL, PL, PI) ASTM D4318
One (1) Laboratory Compaction Test ASTM D1557
For each 500 sq. m. of each layer of compacted fill or fraction
thereof at least one group of three in-situ density tests (ASTM
D1556). The layers shall be placed not exceeding 200 mm in
loose measurement or based on the result of compaction trials.

7.3.2 Aggregate Sub-base Course

For every 300 cu.m. or fraction thereof:
One (1) Grading Test ASTM C136
One (1) Plasticity Test (LL, PL, PI) ASTM D4318
For every 1500 cu.m. or fraction thereof:
One (1) Laboratory Compaction Test ASTM
D1557
For every 2500 cu.m. or fraction thereof:
One (1) California Bearing Ratio Test ASTM D1883
For every layer of 150 mm of compacted depth/ based on the
results of compaction trials:
At least one group of three in-situ density tests (ASTM
D1556) for each 500 sq.m. or fraction thereof.

7.3.3 Concrete
Ready Mix Concrete
For Fresh Concrete
Slump Test ASTM C143

For Structural concrete,

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Compressive strength test on concrete cylinder samples (ASTM

C39)
One (1) set consisting of 3 concrete cylinder samples
shall be taken from each days pouring and to represent
not more than 75 cu.m of concrete or fraction thereof

For Road surface courses

Flexural Strength Test on Concrete Beam Sample (ASTM C78)
One (1) set consisting of 3 beam samples shall
represent a 330 sq. m of pavement, 230 mm depth or
fraction thereof placed each day. Volume of concrete
not more than 75 cu.m.
Cement
Tests: For every 2000 bags or fraction thereof:
One (1) Quality Test
Chemical Test
Physical Test
Aggregates
Tests: For every 1500 cu.m. or fraction thereof:
For a source not yet tested, or failed in previous quality test
One (1) Quality Test:
Grading ASTM C136
Moisture Content ASTM C127
Specific Gravity ASTM C128
Absorption ASTM C127
Soundness Test ASTM C88
Unit Weight ASTM C29
For a source previously tested and passed Quality Test:
One (1) Quality Test for
Grading ASTM C136
Moisture Content ASTM C127
Absorption ASTM C128
For every 75 cu.m. or fraction thereof
Grading Test ASTM C136
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Water
Tests: One (1) Certificate from Project Engineer or one (1) Chemical
Analysis, if source is questionable

Admixtures
Tests: One (1) Certificate from Project Engineer or Mill Certificate per
shipment

7.3.4 Joint Filler (for PCCP and others)

Poured Joint Filler
Test: One (1) Inspection Test each shipment

7.3.5 Masonry Units

Non-load bearing masonry units
Test: One (1) Quality Test* for every 10,000 units or fraction thereof
(*Compressive Strength Test)

7.3.6 Reinforcing Steel Bars

For every 10,000 kg. or fraction thereof for each size
Test: One (1) Mill Certificate for Bending, Tension and Chemical
Analysis
Physical Test for Bending and Tension ASTM 615

7.3.7 High Tensile Wire Strand

For every 20,000 kg. or fraction thereof for each size
Test: One (1) Mill Certificate for Tension and Chemical Analysis
Physical Test for Tension ASTM 416

7.3.8 Metal Members/Structures

Test: Quality Test or Mill Test Certificate for each type of materials
used
Inspection Report for each type and shipment of metal used ASTM
A36

7.3.9 Bored Pile

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1. High Strain Dynamic Method (PDA) shall be 5% of total

number of piles.
2. Low Strain Dynamic Method - 10% of total number of piles.
a. PIT - 10 % of total no. of working piles.
b. Cross-Hole 5 % of total no. of working piles.
3. Static Test / Osterberg Cell Test one pile test (1.0mm dia x
35m) to represent all bored piles with the same design to be
constructed on site. The test pile will be located on the sites worst
ground condition.

7.3.10Welded Connections
Dye Penetrant Test, a non-destructive type of test (NDT) shall
be conducted by an accredited testing company to check 5% of
total welded connections of structural steel members in the
building

7.3.11Fence

Inspection Test for Barbed wire or ASTM A 121 Class I.

One Low-Strain Test (PIT) for concrete sheet pile for entire
fence.

7.3.12Water Testing of Structure

Structures are to be tested against leakage after the precast

and in-situ elements are placed in. Water test shall be
conducted after the surfaces and joints are smooth finished.

7.4 Minimum Test and/or Inspection Requirements Electro-

Mechanical Works

Below is the schedule of minimum test and/or inspection

requirements for electro-mechanical equipment before and/or after
installation. Each test and/or inspection will be carried out on all units
of equipment concerned. Internal tests will be carried out to ensure
that any non-conformity or defect, even minor ones, can be
addressed prior to actual tests in the presence of the client.

Electro-mechanical tests should only commence once civil and

structural works for that particular area have passed all the required
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tests. Proper and documented handing-over of the area should be

observed. It should be free from construction debris and materials. In
addition, all surfaces should be finished in accordance to the
specifications.

7.4.1 Factory Acceptance Test (FAT)

Prior to leaving a manufacturers factory, each item of equipment (as

required in contract specifications) shall be tested in accordance with
the relevant Standards, Specifications or Code of Practice. In the
absence of such, tests shall be performed in a manner subject to the
approval of the client.

The Consortium should inform the client of the production schedule

and give advance notice of the planned FAT, especially if the factory
is located abroad.

7.4.2 Physical and Pre-commissioning Inspections

All delivered equipment should be checked visually (e.g. dimensions,

nameplates) if it corresponds to the approved drawings and
specifications.

Inspections should be carried out on installations to ensure that all are

done properly and are ready for commissioning.

7.4.3 Functional Tests

These pre-commissioning tests shall be carried out to demonstrate

that all individual components/systems are ready for operation and
comply with contract requirements as well as the corresponding
electro-mechanical component specifications.
Two types of test can be conducted during the functional tests.

a. Dry test - conducted to verify if equipment turns in correct

direction by switching on the equipment for a few seconds.
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b. Wet test - carried out by introducing fluid into the system, to check
if it can run normally (e.g without leakage, excessive noise and
vibration, etc).

Functional testing shall be performed according to Work Method

Statement which should be submitted and approved before each
scheduled testing.

Equipment vendor, who will provide the Work Method Statement, and
the Client will be involved in this activity.

7.4.4 Loop Tests and Instrument Checking

A test which begins at the process variable through the controller

then back to the control device to ensure that the system is working
according to the design. Please refer to Project Commissioning Plan
for more details on this matter.

All field, handheld, as well as test instruments, should be provided

with calibration certificates. Before installation, it should be ensured
that none has elapsed the expiration date.

7.4.5 Fire Detection and Alarm System (FDAS)

All components of the FDAS should be tested for functionality:

Smoke Detectors by exposure to smoke canisters
Heat Detectors by applying heat
Manual Pull Station by pulling down the addressable pull station
The corresponding horn strobes should sound the alarm every time
the above activities are carried out. At the same time, the FDAS panel
should indicate the area where the alarm sounded.

7.4.6 Other Electrical Tests

7.4.6.1 Electric Motors

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Tests:Insulation and Continuity Tests according to Philippine

Electrical Code
Phase Rotation Test
Alignment Check as per approved drawings
Vibration and Temperature Check as per manufacturers
recommendation

7.4.6.2 Cables and Wires

Tests: Insulation and Continuity Tests according to Philippine

Electrical Code
Earth Loop Impedance Test according to Philippine Electrical
Code
High Voltage Test according to Philippine Electrical Code

7.4.6.3 Structured Cabling

Copper Cable and Connectors:

Tests:Each RJ-45 Jack connector shall be tested to ensure Category

5e performance.
Each RJ-45 Jack shall be tested for Point to Point connectivity,
by utilizing hand held time domain reflectometers (TDR ),
capable of generating pulses of 100MHz, and of testing that
the following parameters:
Wire mapping for correct polarity
Length for point to point connectivity under 90 meters
Near end cross talk (NEXT)
Resistance
Impedance
Capacitance
Noise
Attenuation
Optical Fiber Cable

Tests:White light tests to confirm end to end connectivity on

delivery to site, after installation and prior to field
termination
After field termination, point to point connectivity shall be
tested on each cable
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7.4.6.4 Earthing system

Test: Ground Resistance Test according to Philippine Electrical

Code
Earth Loop Impedance Test according to Philippine Electrical
Code

7.4.6.5 Lighting and Small Power

The following should be verified for the lighting fixtures:

Indoor Lighting - LED type with power ratings following
specifications in the approved drawings
Perimeter Lightning High pressure sodium lamps mounted on
steel structures
Outdoor Lighting Metal halide floodlight mounted on
wall/structure

Socket Outlets:
All outlets located outside the plant should be verified to be
IP56 rated and with the following specifications:
o Single phase, 230V, with 2 flat pin + E
All breakers should be verified to be of the RCD type.

7.4.6.6 Generator Set

Test: Load Bank Test based on manufacturers recommendation

Source Emission Test in accordance with the Clean Air Act
Noise Level Test to comply with OSHA Standard 29 CFR
1910.95

7.4.6.7 Transformer

Tests: Ratio tests at the rated voltage connection and all tap
connection.
Polarity and phase relation tests on the rated voltage
connection.
Applied potential tests.
Induced potential tests.
Non-load and excitation current at rated voltage on the
rated voltage connection
Resistance measurements of all windings on the rated
voltage connections
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Impedance and load loss at rated current

7.4.6.8 MCC and Switch Gear

Tests: Phase sequence and voltage levels

Sequential operational test of all control circuits including
interlocks.
Insulation Test (Phase to phase, Phase to neutral and Phase
to earth)

7.4.7 Plant Commissioning

This is a process to guarantee that all systems and its components of

an industrial plant are designed, constructed and installed properly as
entailed in the contract requirements.

QA/QC Engineers will run the whole process line with water loaded
then adjust parameters accordingly by aiming at the optimum
performance of the system. Water quality will be measured regularly
and results will be utilized to direct parameter adjustments.

Detailed information on this is discussed in the Project Commissioning

Plan.

7.5 Sign-off and Agreement with Employer

After the completion of a particular testing activity which is deemed

satisfactory by the Employer, QC engineers should secure signed-off
commissioning checklists and test reports from them.

In case of any non-conformance, the comments should be recorded.

These items should be complied with accordingly before obtaining the
signed-off documents.

7.6 Environmental Compliance

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Compliance with the standards set by DENR and other regulatory

bodies (e.g. LLDA) will be strictly implemented by the Consortium
during the course of the project. In addition, all necessary
environmental permits (e.g. PTO, discharge, et al.) will be secured
before operating the plant.

7.7 Health and Safety

The Consortium, including all subcontractors and suppliers, shall

comply with the requirements to operate under the project
environmental management and safety system.

Please refer to the approved HAZOP and HAZCON for further details
on the related general safety provisions.

8 MATERIAL CONTROL STORAGE

8.1 General
The responsibility at the construction site for all material handling
and operation lies with the material controller reporting to project
manager, who with his staff controls records, receiving,
warehousing and issuing of materials. Consortium will assign well
experienced competent personnel to ensure the implementation of
these procedures and the system to this project.

8.2 Receiving

When materials are received at the jobsite in a manner described

in the schedule of contract, a physical count must be made to
verify that the quantity shown in the packing list is correct
conform to shipment record. After the material has been checked,
tagging the material by item according to its nature is done and
the materials receiving report (MRR) is prepared and issued daily
with a brief description of all materials received.
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Whenever discrepancies is found, and over, short and damage

(o.s. & d) report must be prepared to the project manager.

8.3 Warehousing

Materials are turned over to the warehouse section with a copy of

the MRR, after the material has been routed to its proper storage
location. MRR is channeled to stock control.

All materials have designated areas by commodities, which are

clearly defined and identified with appropriate location signs.
Materials required special care, to be protected from direct ray of
the sunlight and to be prevented from heat and humidity and
fragile materials are stored indoor. Also such inflammable
materials such as paint, adhesives, petroleum products and dry
liquid chemical items are stored indoor in the separately installed
storage facilities.

All storage areas are safe, secure, and tidy secure areas, with
access limited to authorized personnel.

Hazardous (flammable, corrosive or poisonous) materials will be

clearly labeled indicating name of substance, danger symbol, etc.
Including safety advice sheet.

Separate areas for drums of chemical will be established with the

appropriate flash point warning signs displayed. No smoking
signs and appropriate fire extinguishers will be on site in
consultation with safety officer.

Where the material has a shelf life, the storekeeper will ensure
that an adequate and effective rotation of stock occurs by
recording dates which will be reviewed prior to issuance.
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All the equipment, materials, tools, etc. in custody will be

safeguarded and ensured that they are treated with due care.

Supplied goods and materials which are not acceptable and

cannot be repaired, shall be returned to the supplier/sub-
contractor, together with clear instructions regarding reasons for
rejection and re-supply instructions. Please see attached proposed
warehouse locations.

8.4 Stock Control

The control system with 20 by 12 cm. bin cards is used on a one
card for one item basis. The card label shows tag or code number
size and a brief description. The back of the card is used to show
material take off quantity, requisition number, quantity ordered,
etc. The front of the card shows the quantity received (with MRR)
number, date & location), quantity issued (with date and
warehouse requisition number) and balance on hand.

8.5 Issuing of Materials

Issuing of material is realized by material issue slip verified and
signed by material superintendent at the written request of the
field engineer based on the work schedule.

Warehouse supervisor confirms job numbers, phase number, and

checks off the material issued against material issue slip to let
warehouse keeping clerk release. Material issue slip is returned to
stock control supervisor with a daily material issue report for
appropriate record.

8.6 Documentation
Copies of forms listed below basically used in the material control
program:
A. Material Receiving Report
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B. Daily Material Issue Slip

C. Over/Short And Damage Report
D. Stock Control Card
E. Material Forecast

9 QUALITY RECORDS
All information formats generated internally, sent externally or
received will be documented. This documentation may be in paper
format, electronic format, records of telephone or personal meetings
or observation notes. Control of this documentation will be extended
to all periods of the Project and functions (e.g. environmental, quality,
safety and health).

The Client will have access to obtain primary records and information
at any time through request according to agreed communication
protocols. At completion of the Project, the Consortium may provide
the client with any primary records required, either soft or hard
copies.

Primary records include all records required to evidence conformance

of work to the Clients Representative and required by the Client to
enable monitoring and quality auditing. The work under the contract
shall be completed in accordance with the provisions of the Contract,
works shall be inspected and tested in accordance with the
requirements in the contract, inspection and test results shall be
analyzed to demonstrate compliance with the contract and
conformance reports shall be issued according to the requirements.

9.1 Lot compliance (Inspection and Test Plan) records

The Project will maintain a lot register and the status will be
progressively updated as work on the lot moves forward.

9.2 Request for information, variation, site instructions and

non-conformance records
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Separate registers will be maintained pertaining to Request for

Information (RFI) variations, client site instructions and Non-
conformance Records (NCR). The registers will be updated regularly
for status changes.

9.3 Drawings, specifications and schedules

The document controller will ensure that the most recent drawings,
specifications and schedules are in use and registered as Issued for
Construction or For Reference as appropriate.

On receipt of drawings, specifications or schedules, the document

controller will:

a) Record the date of receipt

b) Verify if each document received is as stated on the document
transmittal
c) File the document transmittal
d) Input information into the corresponding register

The document controller will maintain a master file of current

drawings, specifications, schedules, RFIs and NCRs and distribute
copies to other key personnel. The document controller will be
responsible for setting up and maintaining document registers and
continuing operation.
As drawings, specifications and schedules are revised or reissued
document control will check that the documents have the necessary
approvals, register the changed documents and distribute them as to
the relevant personnel and subcontractors / suppliers. The document
controller will remove and stamp Superseded on superseded
documents from the master file and will maintain at least one copy of
superseded documentation for record and reference purposes.
Holders of drawings, specifications and schedules are responsible for
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either destroying or identifying and removing from use any

superseded documents in their control

9.4 Construction Manager's Office

Each construction manager shall maintain a file for all audit report
and correspondence showing corrective actions taken in response to
audit findings and recommendation.

9.5 Quality Control Office

The quality control office shall maintain a file of all audit reports and
correspondence showing test results, findings and action taken in
response to audit findings and recommendation.

10 CONFORMANCE & NON-CONFORMANCE

10.1 Conformance reports

A conformance report shall be prepared for each lot and shall be

accompanied by the following:

Inspection and Test records

Analysis of the results to demonstrate compliance with the relevant
standard
As-built drawings, whenever applicable

10.2 Non conformances

10.2.1Non conformity identification and communication

The Consortium aims to rectify deficiencies as soon as possible, to

ensure a solution is found to minimize recurring deficiencies, improve
processes and product quality. Non-conformity will not be taken
negatively, but will be considered as a process of improvement and
will be produced, promoted and received in this tone. NCRs will be
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raised and issued in an even-handed manner; including all

contractors, suppliers, consultants and the project team.

All non-conformities identified will be registered in a designated

register. A non-conformity report (NCR) will be issued for every non-
conformance to the applicable specifications, design standards,
special requirements, drawings or procedures for any conditions
whereby the product or service does not meet contract requirements.
The NCR shall be raised within 24 hours of detection whenever
possible, and created and maintained within the document
management system. The QA/QC Manager will be responsible for
ensuring that all relevant parties are notified of the creation of any
non-conformity reports. He will also be responsible for ensuring all
relevant personnel are consulted regarding close-out instructions.
These parties may include the Client, Regulatory Authorities and
Legislative Authorities as deemed necessary.

To ensure that all quality issues are reported, resolved and not
repeated, the following hierarchy of controls will be used:

a) Elimination of situation causing non-conformance

b) Physical constraints to remove chance of fault occurring during
activity
c) Procedural action to control the occurrence of fault.

Summaries or specifics of NCRs will be reviewed and analyzed as part

of the management meetings, reported and included in management
reviews.

10.3 Corrective Action

Corrective action will be adopted to eliminate the recurrence of non-

conformities. This process will be adopted in the case of recurring
non-conformities, where action is required to eliminate the root
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causes and shall include analysis of the trend of non-conformities,

root cause determination, approval, implementation and monitoring
of the corrective action.

10.4 Preventive Action

Preventive actions are adopted to avoid the root causes appearing.

This process will be used to eliminate potential non-conformities
before their occurrence, by analyzing potential non-conforming
situations during planning of activities and applying the hierarchy of
control to those situations that are deemed of high risk.

11 RISK MANAGEMENT

The Consortium undertakes risk identification and mitigation through

a structured process coordinated by the Project Manager. For quality
activities related to construction there are specification nominated
approvals to control the outputs of the process and material controls
to control the quality of the product. The Consortium will use
internally nominated approvals for those activities it deems of higher
risk, and these will be identified through the as well as non-
conformance rectification actions.

11.1 Identified quality control risks

Risks to the quality control of the Project include non-compliance and

inadequacies of:
Change in law, standards and regulations applicable to the project
Guarantees of the treatment
Approval Procedures
Inflation and currency exchange fluctuation

The risk register will initially define and manage common foreseeable
risks and also assist in determining which project activities involve
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levels of risk requiring formal documented controls. The Consortium

will hold an initial risk workshop to transfer the tender stage risk
assessment and identify and assess the project scope of works and
the subsequent project specific activities and appropriate control
measures in accordance with relevant client/company/project
standards, regulations, standards and Codes of Practice.

For Quality specific risks the preparation of management documents

including construction procedures, method statements, inspection
and test plans will identify the key risks and aspects of the project.
These will be verified internally through objective evidence and
observation/inspection of site activities using trained personnel.

12 AUDIT FUNCTION
12.1 Purpose
The periodic review of actions and of inspection results that all works
is being performed in accordance with contractual requirements and
that deviations are being corrected or accepted.

12.2 Scope
The audit program described in this section applies to all quality
related work performed by consortium or subcontractors during
construction of the project.

12.3 Responsibility
The construction manager has overall responsibility for the
implementation of an effective quality control program. Planning and
implementing the audit program shall be done under the direction of
the QA/QC Manager.

12.4 Audit
12.4.1Audit Team

Audit shall be performed by team of auditors who are familiar with,

but not directly responsible for, the work of activities being
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audited. The audit team shall be headed by the QA/QC Managers

supervision and shall include such other personnel as he may
appoint to secure the coverage desired in the audit.

12.4.2Audit Schedules

The type of frequency of audits shall be recommended by the

QA/QC Engineer and approved by the Project Manager. The audit
schedule shall then be prepared and issued by the QA/QC Engineer,
audit shall be done. Initial audit schedule shall be conducted six
months after the project start, succeeding audit shall be once a
year. The activities which shall be audited shall be as follows, but
not limited to:
A. Overall Quality Control Program
B. Document Control
C. Field Procurement Control
D. Materials And Equipment Control
E. Test Control

12.4.3Unscheduled Audits

Unscheduled audits and spot checks may also be conducted at the

discretion of the QA/QC Manager when the following condition
exists.
A. Areas of work and activities are newly started.
B. Receipt of verbal or written reports of deviations of
deficiencies.
C. Previous audit of an area indicates need for follow-up.
D. Period of time established in an earlier for implementing
corrective action has elapsed.

12.4.4Audit Planning

A written plan shall be prepared prior to conduct of the audit. Each

audit team member shall review all documents which prescribe the
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work or activity to be audited, and shall prepare a checklist of items

to be audited. The audit team leader shall review and approve the
audit plans and checklists prepared by each audit team member prior
to conducting the audit.

12.4.5Notice of Audit

The construction manager of the job to be audited shall be notified at

least three working days in advance of audit. At that time he shall be
advised of the proposed audit agenda. The audit team leader shall
coordinate with the chief field engineer to assure that the audit
conduct will not unduly affect construction activities.

12.4.6Audit Conduct

The audit shall proceed, seeing the prepared plans and checklists as a
guide. However, the audit team leader may deviate from the plan
when progress in the audit reveals the need in order to properly cover
the scope of audit. A record of the activity audited, names and
responsibilities of persons contacted, and the audit findings shall be
documented in the audit report checklists used shall become part of
the audit record file, and shall indicate items that were checked and
found acceptable as well as those found to require corrective actions.

12.4.7Audit Review Meeting

The audit team leader shall schedule a post audit meetings with
construction manager to discuss audit findings and recommend
corrective actions.

12.4.8Audit Report
The audit findings and recommendations shall be documented in an
audit report issued to the construction manager of the job audited.
An information copy of each audit shall be transmitted to the project
manager responsible for the site audited.
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12.4.9Audit Close Out

The chief field engineer on the job audited shall assure the required
corrective actions are completed within the specified time. When
action on the findings is complete, he shall report such action to the
QA/QC Manager.

The QA/QC Materials Manager, the Project Manager and the manager
of engineering, shall review the action reported for each finding and,
if action is considered satisfactory, issue a close out report.

13 INSPECTION CHECKLIST & LABORATORY FORMS

13.1 See attached sample for the following forms:

Inspection Request Forms

Request for Inspection of Work (RIW)
Request for Rebars Inspection (RRI)
Request for Formworks Closure (RFC)
Concrete Pouring Request (CPR)

Laboratory Forms
(Third Party Laboratory Testing Center format)

Document Submittal Forms

Request for Information Form
Request for Materials Approval Form
Request for Sub-Contractors Approval Form
Shop Drawing Submittal Form
Technical Submittal Form
Transmittal Form

Reporting Forms
Daily Site Report (Weather Chart)
Weekly Report
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