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PHILIPPINE NATIONAL RAILWAYS PROJECT PHILIPPINE NATIONAL RAILWAYS Prestress Sleepers Fabrication
INSPECTION STAGE
No. QUALITY ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA & FREQUENCY OF TEST RESPONSIBLE PERSON VERIFYING DOCUMENT
FFC HENC
Project Manager
1.0 Review of Scope of Work and Drawings Contract Documents Contract Documents for Costruction QA/QC Head Contract Review Records
Design Engineer
Cement (Type I) Portland cement shall be factory produced by Quality Control Supervisor Material Approval Sheet
the cement manufacturer and shall comply with Materials Supervisor Mill Certificate
provisions of ASTM C-150 Quality Test
Aggregates for Concrete Fine and Coarse Aggregate shall comply with the Quality Control Supervisor Material Approval Sheet
relevant provisions of ASTM C33 Materials Supervisor Quality Test
Fine aggregate shall be washed natural sand
conforming ASTM C33
Coarse aggregate shall be well graded and
shall conform to ASTM C33
Admixture for Concrete An admixture to the concrete may be used if Quality Control Supervisor Material Approval Sheet
approved by PNR in writing . High performance Materials Supervisor Brochure
superplasticising admixture (type F) and shall
comply with ASTM C 494 and does not contain
calcium chloride.
Admixture for the production of air entrained
concrete shall comply with the requirements of
ASTM C 250
Fly ash and natural pozzolans for use in concrete
shall comply with the requirements of ASTM
C 618
Ground Granular blast furnace cements, for use in
concrete shall comply with the requirements
of ASTM C989
PROJECT TITLE CLIENT WORK ITEM DOCUMENT REF.
PHILIPPINE NATIONAL RAILWAYS PROJECT PHILIPPINE NATIONAL RAILWAYS Prestress Sleepers Fabrication
INSPECTION STAGE
No. QUALITY ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA & FREQUENCY OF TEST RESPONSIBLE PERSON VERIFYING DOCUMENT
FFC HENC
Steel Reinforcement Bars Bar reinforcing steel shall be hot rolled non - Quality Control Supervisor Material Approval Sheet
weldable deformed, new billet bars conforming Materials Supervisor Laboratory Tensile Test Report
to ASTM A615 , Grade 40 bar ≤ Ø12 and Mill Certificate
Grade 60 bar ≥ Ø16 unless otherwise specified
on drawing, or its equivalent under PNS -49
Steel reinforcement shall be free from loose mill
and rust scale and from coatings that may destroy
or reduce the bond.
Steel reinforcement shall bear mill identification
symbols and shall be tagged with the size and
marked number so that different types may be
identified. They shall be stored off the ground.
Testing of steel reinforecement shall conform to
ASTM A370
Every batch of steel reinforcement delivered to the
Plant shall be tested to verify mass and tensile
properties for every 10,000 kg of fraction thereof. Material Sample
The test shall consists of 3 specimens for each bar
size.
Pre-stressing Steel Prestressing steel must be 0.5" diameter, 7-wire Quality Control Supervisor Material Approval Sheet
high tensile low relaxation strand conforming to Materials Supervisor Laboratory Tensile Test Report
ASTM 416. Prestressing steel shall have a minimum Mill Certificate
ultimate strength of 1860 Mpa corresponding to
a breaking load of 183 kN and a yield load at 1%
extension of 165 kN. Test methods on prestressing
pre-stressing steel shall be done according to
ASTM A370. Strand chucks shall be capable of
anchoring the strand without slippage after seating.
Tying Wire Tying wire for steel reinforcement shall be gauge Plant Engineer Material Sample
16, GI wire conforming ASTM A82 Quality Control Supervisor
Visual, Physical Materials Supervisor
PROJECT TITLE CLIENT WORK ITEM DOCUMENT REF.
PHILIPPINE NATIONAL RAILWAYS PROJECT PHILIPPINE NATIONAL RAILWAYS Prestress Sleepers Fabrication
INSPECTION STAGE
No. QUALITY ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA & FREQUENCY OF TEST RESPONSIBLE PERSON VERIFYING DOCUMENT
FFC HENC
Spacer/Cover Blocks Cover Blocks and spacers shall be made of Plant Engineer Material Sample
concrete with 10mm aggregate size and Materials Supervisor
otherwise produced to the same application as Quality Control Supervisor
the sorrounding concrete. Wire cast in the block
for the purpose of tying it to the reinforcement
shall be gauge 16 GI wire in accordance to
ASTM A 82
Visual, Physical
Neoprene Bearing Pad Shall be 10mm thickness and Hardness 60 Quality Control Supervisor Material Approval Sheet
Materials Supervisor Material Sample
Brochure
Anchor Bolt Embedments Anchor bolt shall conform to ASME B18.18.2M Field Engineer Material Approval Sheet
Specifications. Must be free from rust scale that Field QC Engineer Material Sample
may damage concrete bond. Erection Engineer Mill Certificate
Water Water for use with cement or in contact with Plant Engineer Visual, physical
potable water mains and installations shall be Quality Control Supervisor
potable clean and free from alkali, oil and Materials Supervisor
organic matter.
3.0
Material Storage
Aggregates Shall be stored on hard impervious surface Warehouse Supervisor Quality Inspection Report
Acceptance Report
Water Water storage tank shall be shaded from the Warehouse Supervisor Quality Inspection Report
hot sun Acceptance Report
Prestressing Steel Shall be free from direct sunlight and water Warehouse Supervisor Quality Inspection Report
exposure to avoid rust Acceptance Report
Steel Reinforcement Bars Stacking in groups, clear off ground and Warehouse Supervisor Quality Inspection Report
labelled for easy identification of deliveries, Acceptance Report
sizes and types.
PROJECT TITLE CLIENT WORK ITEM DOCUMENT REF.
PHILIPPINE NATIONAL RAILWAYS PROJECT PHILIPPINE NATIONAL RAILWAYS Prestress Sleepers Fabrication
INSPECTION STAGE
No. QUALITY ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA & FREQUENCY OF TEST RESPONSIBLE PERSON VERIFYING DOCUMENT
FFC HENC
Concrete Mix Design The mix design shall be submitted to PNR Quality Control Supervisor Design Mix Test Report
for codifying at least fifteen (15) days prior Materials Supervisor
to placing concrete or before the start of concrete
production.
Unless otherwise described in the Contract, the
cementitious content of concrete shall not exceed 440
kg/m³, the maximumwater-cementitious ratio is 0.45
and the maximum size of aggregates shall not exceed
25% of the minimum thickness of the structural
member with an upper limit of 19mm
Mix Details for Mixing In accordance with ASTM C31 and C39 Quality Control Supervisor Trial Mix Report
Materials Supervisor
Testing of Cylinders Design Mix Trial Batch with twelve (12) cylinder for test at ages
12hrs, 24hrs, 3 days, 7th, 14th, and 28th day strength
with two (2) samples each.
PROJECT TITLE CLIENT WORK ITEM DOCUMENT REF.
PHILIPPINE NATIONAL RAILWAYS PROJECT PHILIPPINE NATIONAL RAILWAYS Prestress Sleepers Fabrication
INSPECTION STAGE
No. QUALITY ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA & FREQUENCY OF TEST RESPONSIBLE PERSON VERIFYING DOCUMENT
FFC HENC
6.0 Formworks - Faces in contact with concrete shall be free Plant Engineer Precast Inspection Report
from adherent grout, projecting nails, splits QC Supervisor Form Oil brochure
& other defects.
- Joints shall be sufficiently tight to prevent
leakage of cement grout.
- 25 x 25 mm chamfer on exposed corners
( if specified )
- Forms shall be applied with form oil or
approved equal.
- Deflection: < 2 mm on surfaces.
- Minimum concrete cover shall be strictly
followed.
7.0 Fixing Reinforcement Based on approved shop drawings, Plant Engineer Precast Inspection Report
Precast Mortar Blocks Shall be placed at a maximum spacing of 1.0 QC Supervisor Concrete Pouring Request
meter and always near the edge of
reinforcement bars or formworks.
PHILIPPINE NATIONAL RAILWAYS PROJECT PHILIPPINE NATIONAL RAILWAYS Prestress Sleepers Fabrication
INSPECTION STAGE
No. QUALITY ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA & FREQUENCY OF TEST RESPONSIBLE PERSON VERIFYING DOCUMENT
FFC HENC
Compacting Compaction of concrete shall be in accordance with Plant Engineer Concrete Pouring Request
ACI 309-72. Compaction should use High QC Supervisor
Frequency Vibrator
Sufficient vibrator should be provided to compact
the concrete quickly & spare should be available.
Vibrations of reinforcements or formworks
shall not be permitted.
Internal vibrator should be used
Curing Immediately after finishing, the exposed surface of Plant Engineer Concrete Pouring Request
concrete should be covered with canvass. After the QC Supervisor
concrete has hardened sufficiently,the sheeting should
be
should be removed and the surface should be sprayed
with water.
11.0 Stressing and Detensioning Sect D - 3.1.3 (S1-020) Layout of strands along the bed must be according Plant Engineer Detensioning Request
PHILIPPINE NATIONAL RAILWAYS PROJECT PHILIPPINE NATIONAL RAILWAYS Prestress Sleepers Fabrication
INSPECTION STAGE
No. QUALITY ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA & FREQUENCY OF TEST RESPONSIBLE PERSON VERIFYING DOCUMENT
FFC HENC
12 Formwork Removal Formwork should not be removed less than 18 hrs. Plant Engineer Formwork Removal Request
13 Surface Finishes All exposed concrete surfaces either rough Plant Engineer Precast Inspection Report
finish, fair finish or fair worked finish shall QC Supervisor Outgoing Inspection Report
have a dense smooth finish, free from honeycombing,
form marks, fins and other irregularities.
Visual Inspection : 100%
14 Testing Concrete
Fresh Concrete Sampling & Testing of fresh concrete shall be Materials Supervisor Laboratory Test Result
be performed in accordance with ASTM Laboratory Technician
C39, ASTM C 31 and ASTM C172.
Obtain cylinder samples at the rate of three
(2) sets of five (8) samples for each batch
poured.
Test two (2) cylinders at detensioning, two (2)
cylinders each at 7th, 14th and 28th days.
Slump Test of Concrete Slump test will be done for each batch of
concrete at the time of its being placed in position in
accordance with ASTM C143. Maximum slump for
the direct poured concrete is 4 inches while 6 inches
for pumcrete poured concrete.
15 Repair of Concrete Surface Visul Inspection, 100 % Field Engineer Quality Inspection Report
PHILIPPINE NATIONAL RAILWAYS PROJECT PHILIPPINE NATIONAL RAILWAYS Prestress Sleepers Fabrication
INSPECTION STAGE
No. QUALITY ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA & FREQUENCY OF TEST RESPONSIBLE PERSON VERIFYING DOCUMENT
FFC HENC
16 Stocking Storage area for precast units is provided with Field Engineer Precast Installation Request
must be prepared. All inspection request must be Field QC Engineer Inspection Request
approved by PNR. Erection Engineer Inspection Notice
Abbreviations / Definitions
H HOLD Prior notice, attendance and clearance by the concerned party is required before next activity
W Witness Prior notice, but work may proceed without waiting for acceptance by concerned party.
R Review A stage during construction activity where only review of records will be done.
S Surveillance Inspection during construction activity, but the work may proceed.
M Monitor Monitor Activity
QC Quality Control
AD Approved Document
PD Prepare Document
RD Review Document
FF CRUZ AND CO., INC.
INSPECTION STAGE
ACCEPTANCE CRITERIA & FREQUENCY OF VERIFYING DOCUMENT (X) :
No. QUALITY ACTIVITY CONTROLLING DOCUMENT RESPONSIBLE PERSON
TEST SUBMIT
FFC-JEC-KEL MWCI
Cement SES Section 2 Clause 2.10.3 Cement used for mortar shall be OPC Civil Supervisor Material Approval Sheet (x)
Type I complying to ASTM C91 Costruction Engineer
Sand SES Section 2 Clause 2.12.1 Shall comply with provisions of Civil Supervisor Materials Approval Sheet (x)
ASTM C 144 Costruction Engineer
Water Water to be used shall be clean and free from Civil Supervisor
organic matter. Costruction Engineer
Concrete Blocks SES Section 2 Clause 2.29.2 Concrete Hollow Blocks shall comply with Civil Supervisor Material Approval Sheet (x)
the provisions of PNS 16. Costruction Engineer
Submit samples for MWCI approval.
2.0 Mortar SES Section 2 Clause 2.30 Shall be mixed using one-bagger mixer Civil Supervisor Inspection Report
approved by MWCI Costruction Engineer
Mortar mix proportion:
Non - Load Bearing = 1:6 mix, M8
Load Bearing : 1:3 mix , M6
Mortar which has begun to set or which
has been site-mixed for a period of more
two hours shall not be used.
Plastering SES Section 6 Clause 6.1 For fair faced walls use blocks having Civil Supervisor Inspection Report
unblemished surfaces and clean arises. Costruction Engineer
Ensure mortar dropping do not deface the
wall.
Cement plastering shall normally be
applied in one coat and batches shall be
used as soon as possible after has
been added. The total thickness of the coat
shall be of the order of, but not exceed,
20mm (3/4 " thk).
Concrete masonry and hollow block
surfaces shall be dampened by brushing or
spraying with clean water, mixed 1 part
cement to 5 parts water.
Plaster mortar proportions is 1 volume
cement to 3 volumes of sand, together
with water.
4.0 Finished Wall Protection Protection from rapid drying = 2 days Civil Supervisor Inspection Report
minimum. It shall kept moist. Costruction Engineer
Temporary props and supports shall not
be removed without MWCI's approval.
5.0 Termite Protection Durban 4TC or Tribute (Fenvalerate) or any Civil Supervisor Inspection Report
(if specified) approved equivalent should be used in Costruction Engineer
Aggregates accordance with manufacturers
recommendation.
Abbreviations / Definitions
H HOLD Prior notice, attendance and clearance by the concerned party is required before next activity
W Witness Prior notice, but work may proceed without waiting for accpetance by concerned party.
R Review A stage during construction activity where only review of records will be done.
S Surveillance Inspection during construction activity, but the work may proceed.
M Monitor Monitor Activity
QC Quality Control
AD Approved Document
PD Prepare Document
RD Review Document
FF CRUZ AND CO., INC.
INSPECTION STAGE
ACCEPTANCE CRITERIA & FREQUENCY OF VERIFYING DOCUMENT (X) :
No. QUALITY ACTIVITY CONTROLLING DOCUMENT RESPONSIBLE PERSON
TEST SUBMIT
FFCCI MWCI
Surveying & Setting Out: Review of Drawing control index & IFC Construction Engineer
1.0 "Issued for Construction" IFC Stamp Respective Drawing
Drawing Drawings Surveyor
No damage to instruments
Survey Reference Points To be transferred to site and protected. Construction Engineer Survey Report
Any other survey point stations used must also
Civil Supervisor/Surveyor
be recorded.
Survey and Setting-out IFC Drawing Construction Engineer Setting-out Report
Civil Supervisor/Surveyor
Take levels on a 10 meters grid or as per job
Construction Engineer
Setting of Levels requirement before the start of work, recorded Civil Supervisor/Surveyor
Survey Levelling Sheet
on drawings as provided by MWCI
Construction Engineer Inspection Record
2.0 Assessment of Ground Condition Stable ground condition Civil Supervisor/Surveyor Respective Drawing
Construction Engineer
10.0 Preservation of Excavation Excavation free from water Civil Supervisor
Safety Engineer
Water Quality Shall be clean and free from organic matter, Construction Engineer
23.0 (use of water other than chlorides, sulphates, waste material and other Civil Supervisor Laboratory Test Report
tapped water) harmful substances. Third Party Laboratory
Abbreviations / Definitions
H HOLD Prior notice, attendance and clearance by the concerned party is required before next activity
W Witness Prior notice, but work may proceed without waiting for accpetance by concerned party.
R Review A stage during construction activity where only review of records will be done.
S Surveillance Inspection during construction activity, but the work may proceed.
M Monitor Monitor Activity
QC Quality Control
AD Approved Document
PD Prepare Document
RD Review Document