PQPRev 2 EBEF

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DOCUMENT TYPE AND TITLE
CONSTRUCTION OF EAST BANK ENTRANCE FACILITY AT THE PORT OF NGQURA
DOCUMENT INFORMATION
ORIGINATOR: ACTIVITY: TYPE OF DOCUMENT:
CQA Manager Quality Assurance & Control Project Quality Plan
DOCUMENT CONTROL NUMBER
Company no Contract no Discipline Originator Revision

DOCUMENT CHANGE RECORD
REV DATE SECTION (S) OF CHANGE DESCRIPTION OF REVISION
PROJECT START DATE PROJECT COMPLETION DATE

DATE DATE:
PREPARED REVIEWED REVIEWED APPROVED
ASSISTANT PROJECT QUALITY MANAGER CONSTRUCTION PROJECT MANAGER

MANAGER MANAGER
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The copyright in this document and the information contained therein is the exclusive property of TORO YA AFRICA AND SOCRASYNC JV. Acceptance of this document constitutes
an agreement that it will be treated as confidential and neither the document nor the information contained therein will be used for any purpose other than that for which it was originally
intended. This document is not to be communicated, disclosed, copied or published to any third person except as previously authorised by the Project Quality Manager.
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TABLE OF CONTENTS
1. INTRODUCTION......................................................................................................................................................6
1.1 SAFETY, HEALTH, ENVIRONMENTAL AND QUALITY (SHEQ) POLICY STATEMENT......................................7
1.2 PROJECT LIMITS OF AUTHORITY, QUALITY STAFF RESPONSIBILITIES AND KEY PERSONNEL ORGANOGRAM
7
1.3 PROJECT DESCRIPTION........................................................................................................................ 8
1.4 PROJECT RISKS................................................................................................................................... 8
1.5 PROJECT OBJECTIVES AND TARGETS.................................................................................................... 8
2. COMMUNICATION AND DOCUMENT DISTRIBUTION AND CONTROL.................................................9
2.1 PROJECT COMMUNICATION................................................................................................................... 9
3. TORO YA AFRICA AND SOCRASYNC JV SUPPORT FUNCTIONS...........................................................11
4. PROJECT CONTROL AND DATA PACKS.......................................................................................................11
4.1 DOCUMENTATION CONTROL................................................................................................................ 11
4.2 PROJECT QUALITY MANAGEMENT AND DELIVERY.................................................................................14
4.3 DESIGN COORDINATION (REFER TO GST 001 DESIGN CONTROL)........................................................15
4.4 PROJECT QUALITY ASSURANCE AND ISO 9001...................................................................................15
4.4.1 ROLES & RESPONSIBILITIES........................................................................................................ 15
5. SITE QUALITY INSPECTION AND CONTROL..............................................................................................18
5.1 PROJECT QUALITY CONTROL PLAN..................................................................................................... 18
5.2 PROJECT METHOD STATEMENTS......................................................................................................... 18
5.3 QCP’S............................................................................................................................................... 19
5.4 FIC’S AND FIR’S................................................................................................................................ 19
5.5 AUDITING........................................................................................................................................... 19
5.6 SD PROCEDURES.............................................................................................................................. 19
5.7 SUBCONTRACTOR COORDINATION....................................................................................................... 20
5.8 INSPECTION AND TESTING................................................................................................................... 20
5.9 INSPECTION, MEASURING AND TESTING EQUIPMENT............................................................................23
6. APPROVED INSPECTION AUTHORITY..........................................................................................................24
6.1 STORES / PROTECTION OF THE WORKS (HANDLING, PACKAGING, STORAGE AND DELIVERY).................24
6.2 SPECIAL PROCESSES AND PROCEDURES............................................................................................. 24
6.3 MATERIAL SPECIFICATIONS, TRACEABILITY AND CERTIFICATION............................................................24
6.4 NON-CONFORMANCE, FEQ’S, CONCESSIONS, EARLY WARNINGS AND CE’S..........................................25
6.5 PROJECT SPECIFIC SUPPORT FUNCTIONS........................................................................................... 25
7. PROCESS REVIEW AND IMPROVEMENT......................................................................................................25
7.1 MONITORING AND MEASURING............................................................................................................ 25
7.2 PRODUCT NON-CONFORMANCES......................................................................................................... 26
7.3 CORRECTIVE ACTION REQUEST AND REPORTING.................................................................................27
7.4 SERVICE AND MAINTENANCE PLAN...................................................................................................... 27
8. QA DATA DOSSIER...............................................................................................................................................27
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an agreement that it will be treated as confidential and neither the document nor the information contained therein will be used for any purpose other than that for which it was
originally intended. This document is not to be communicated, disclosed, copied or published to any third person except as previously authorised by the Project Quality Manager.
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ANNEXURE A: ORGANOGRAM………………………………………………………………….…….29
ANNEXURE B: AUDIT DATE SCHEDULE………………………………………………………….….
….31
ANNEXURE C: QA DATA DOSSIER…………………………………………………………….……...34
ANNEXURE D: METHOD STATEMENT REGISTER……………………….……………………..….….37
ANNEXURE E: QCP REGISTER……………………………………………………………………….39
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LIST OF ACRONYMS
ORIGINATOR
ACC Accounts GFR General Foreman
CRD Contracts Director FRM Foreman
CC Cost Controller QAM JV Quality & Assurance Manager
CEO Chief Executive Officer HRM HR Manager
CFO Chief Financial Officer QS Quantity Surveyor
CM Construction Manager SUR Surveyor
PP Project Planner PM Plant Manager
COO Chief Operations Officer SCC Site Cost Controller
PQM Project Quality Manager SCL Site Clerk
HSM Health & Safety Manager QCC Quality Control Clerk
HSO Health & Safety Officer TYAS Toro Ya Africa and Socrasync JV
DSO Designated Environmental Officer
SDO Supplier Development Officer
DOC Document Controller
DSM Design Manager
ECO Environmental Controlling Officer
ACM Assistant Construction Manager
ACTIVITY OR TRADE
BLD Building Works FIN Finance
BOD Basis of Design ORG Organisation
CIV Civil Works QAS Quality Assurance
CMS Company Management System QCO Quality Control
ENV Environment SHE Safety, Health and Environment
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TYPE OF DOCUMENT
CSP Company System Procedure REG Register
DWG Drawing SCH Schedule
MOU Memorandum of Understanding SCP Supplementary Company Procedure
MS Method Statement SFD Standard Form Document
OCP Operational Control Procedure SMP Service and Maintenance Plans
OMD Operational Management Document SSP Site Supplementary Procedure
PQP Project Quality Plan WDP Works Design Plan
PRG Programme WQP Works Quality Plan
QCP Quality Control Plan PQCP Project Quality Control Plan
GST General Site Transmittal GCP General Site Procedure
CAR Corrective Action Request IMTE Inspection Measuring and Test Equipment
PSS Supervisory Satisfaction Survey CSS Client Satisfaction Survey
PAR Preventive Action Request
Reference Documents: Influence:
ISO 9001: 2008 & ISO 9001:2015 Reference and Control
QAL-STD-001 Control
Tender Documents Reference
Contract Documents NEC 3 Control
Company Policies and JV Contractual Documents Reference
SANS Schedules Control
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Figure 1: INTEGRATED PQP SYSTEM DIAGRAM
1. INTRODUCTION
TORO YA AFRICA AND SOCRASYNC JV Reference documentation: Project Quality

Management Plan.
This Project Quality Plan (PQP) defines the Management System that shall be applied by
TORO YA AFRICA AND SOCRASYNC JV for the : CONSTRUCTION OF THE EAST BANK
ENTRANCE FACILITY AT THE PORT OF NGQURA and it is the Project’s main reference for
all quality matters including objectives and targets set by TORO YA AFRICA AND
SOCRASYNC JV Management as well as the Employer.
In definition of the above statement, this PQP encompasses the Quality Management System,
for all TYAS JV activities for this project, which refers to, or establishes, procedures to control
and manage the various activities that may have an impact on product and construction
quality.
The TORO YA AFRICA AND SOCRASYNC JV Quality Management Policy is included on the
Project Quality Plan and defines the JV’s commitment towards Quality Control and Assurance.
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The success of the policy and its application will be reviewed at the 3 monthly management
meeting and these meetings will co-inside with the External audit dates and are indicated on
the Audit Schedule attached as Annexure B. This is a live control document and will be
reviewed, adjusted and distributed as and when needed.
TYAS’s activities for the project are diagrammatically represented on the PQP Integrated
System Diagram (refer to Figure 8.4 Page 6).
1.1 Safety, Health, Environmental and Quality (SHEQ) Policy Statement
Our Quality Policy specifies the Degree of Excellence as “all activities of the organization will
be carried out in a systematic manner in accordance with defined and documented Policies
and Procedures, will meet applicable legislative requirements, will be visible and auditable,
and will ensure that the needs of employees and Stakeholders are met.
TYAS JV is committed to providing construction and consultancy services that satisfy our
customers’ needs and expectations in safety, quality & reliability while complying with all
relevant requirements, regulations, legislation and standards. We are committed to continually
improving how we deliver our services to our customer through the understanding of their
requirements and application of consistent methodology and disciplined processes.
Our top management is committed to continually improving the effectiveness of our quality
management system and the customer experience through training & development of
employees and sub-contractors, continuous collection of customer feedback, internal and
external auditing of our standards and procedures, setting and reviewing our Quality
Objectives each year and ensuring the suitability of the Quality Management System so we
can deliver customer satisfaction on a suitable basis.
This can only be achieved through the support of our employees & sub-contractors and their
compliance at all times with our processes and procedures.
1.2 Project Limits of Authority, Quality Staff responsibilities and Key Personnel
Organogram
On the Project, certain project specific Limits of Authority have been defined regarding Project
Procurement and Project Administration for the relevant activities. (Limits of authority TYAS
010 document & specimen signatures TYAS 020). All construction personnel, including Sub-
contractor’s managers will be trained on the quality control system and procedures and will be
responsible to conduct all visual pre-inspections, prior to arranging inspections by senior
construction or quality personnel. Since the Assistant Construction Manager, General
Foreman and the Foremen will have to conduct visual inspections and Equipment testing,
relevant training of staff will be conducted and experience on Equipment must be confirmed in
relevant documentation. The management staff for quality on site will comprise of the quality
Manager and the quality control clerk. The key personnel organogram is attached as
Annexure A. The Head Office Support Organogram has been compiled and approved.
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1.3 Project Description

CONSTRUCTION OF SECURITY PEIMETER FENCE AT THE EAST BANK ENTRANCE
FACILITY AT THE PORT OF NGQURA.
1.4 Project Risks
1.4.1 Variations and Corrective Action Requests to Scope of Works
Corrective Action Requests will be issued in writing to the Client and managed by the
Contracts Manager. This includes compensation events and the finalization and approval of
Provisional items, as per BOQ.
The Site Management construction team QS will perform evaluations on the Variations and
Corrective Actions, to determine the time and cost implications.
Costing is done on a daily and a weekly basis on site and discussed in the site meetings –
once-a-week. The Assistant Project Manager is responsible for costing and Payment controls.
A cost report will be presented at the weekly meetings. Any Compensation events will be
added and reported on separately.
TYAS Reference Documentation: Operational and Project Risk Management
TYAS manages risks at both a project and operational level.

On this project, the identified risks have been noted on the register. These risks include, but
are not limited to the following categories:
 Physical Conditions;
 Site Conditions;
 Contractual and Commercial;
 Subcontractors;
 Own Performance;
 Human Resources
These risks are reviewed at the Risk Review at weekly Meetings, where the Risk Register is
updated by the Client’s Risk Manager. The Project Risk Register is further reviewed at the
Point Meetings and forms part of the agenda.
1.5 Project Objectives and Targets
The Toro Ya Africa and Socrasync JV Key Objective will be measured as follows:
Reference Table in item 5.5
JV and Site SHEQ Compliance
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JV and Site SHEQ Internal and External Audits

SHEQ External Audits occur on a three monthly basis to ensure compliance with the ISO
9001 Standards. Site Internal Audits which include sub-contractor audits will be conducted on
a monthly basis. An External Auditor has been appointed to conduct the three-monthly
external audits.
Review of the effectiveness of the SHEQ system:
The SHEQ Site Management, along with JV Project management and External Auditors, will
evaluate the effectiveness of their SHEQ System on a quarterly basis by completing a SHEQ
Report. This report is submitted and evaluated by the Client. Contents of the report will
conform to the ISO 9001 standards.
Project Manager / Supervisor (PSS) Satisfaction Survey:

Monitoring of Client Satisfaction will occur during Internal Audits. The Project Manager will
record and evaluate the results and record it on the SFD Report.
Client (CSS) Satisfaction Survey:
At 90% completion of the project, the Contracts Manager will forward a questionnaire Form
(SFD) to the client.
Client Questionnaire feedback on TYAS performance is reported to TYAS Management in the
Internal Audit Report and at the Management Review.
2. COMMUNICATION and DOCUMENT DISTRIBUTION and CONTROL
TYAS Reference Documentation: Internal Communications / NEC Core Clauses
Section 13
The Contracts Manager is responsible for the Site organogram. Latest Site Organogram will
be displayed at the Site office of the Construction Manager.
2.1 Project Communication
All formal documented project communication will occur through Transmittal emails (Electronic
Copies), distribution of project documentation (Hard Copies) and records storage (Data
Packs).
The TYAS Quality system provides for Field Engineering Query (FEQ), Compensation Events
(referred to as CE) and Early Warning, whenever there is a fundamental deviation from
reference designs or a cost implication.
Internal Communication
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Internal communication will be addressed to all affected personnel at various levels in line with
the organisational charts (one level up / one level down / lateral).
Records of all relevant internal communication (e.g. minutes of meetings, internal emails) will
be retained by the Document Controller.
External Communication
External parties can contact TYAS Head office telephonically or via email.
Any complaints, compliments or feedback made by an external party using any one of above
methods must be forwarded to the Contracts Director, who will ensure it is recorded and
controlled by completing an SFD and distributing to Interested and Affected Person/s Register
(IAP Register).
Response to the query or complaint must be given to the external party as soon as is
reasonably practicable.
Any communication to external parties and customers that could impact on the image of TYAS
or the Employer (client) must be approved by the Communications Manager (TYAS Head
Office).
Client Communication
Client details must be kept on record; all communication should be through written
communication, including a Transmittal Control Document and must be sent to TGC
Document Control. Relevant persons on the distribution list may be copied with the transmittal.
PROJECT MEETINGS
External Project Meetings
Client Monthly and Fortnightly Meetings (chaired by the Project Manager) – Scope of work
Sec 6.1
Internal Project Meetings
TYAS Reference Documentation: OCP Project Review and Estimating

SHEQ Kick-off Meeting (chaired by SHEQ Management)
After the transfer meeting, a SHEQ kick-off meeting will determine the process control
requirements. This meeting is attended by Project Management and SHEQ Personnel (SFD
controlled) and will take place once Site is Established and prior to Construction work
commencement.
Transfer Objective and Point Meeting (chaired by Project Manager)
The Transfer, Objective and Point Meetings for the Project will be scheduled as follows:
Transfer Meeting Completed
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Point Meeting 20% TBC

These meetings will be attended by Management as defined in Procedure OCP 003. These
meetings will be recorded as minutes and will be distributed as per distribution list.
Production / Technical Meeting (Chaired by Construction Manager)
A formal production meeting shall take place on a weekly basis from the commencement date
until the issue of the Taking over certificate. The meeting is chaired by the Construction
Manager and attended by all the heads of sections and / or sub-contractors on the project.
Subcontractor Meetings: (Chaired by Assistant Construction Manager)
A formal work planning meeting shall take place on a weekly basis from the commencement
date until the issue of the Taking over certificate. The meeting is chaired by the Assistant
Construction Manager and attended by the subcontractor staff.
Management Review
TYAS Reference Documentation: OCP 002 Management Review and Improvement. This
meeting will take place on quarterly basis.
SHEQ Management,
Together with Project Management, SHEQ Management will evaluate the effectiveness of the
SHEQ System on a quarterly basis. On completion a copy will be forwarded to the SHEQ
Department (Head Office). This information will be analysed and presented to management at
the JV Management Review as above.
3. TORO YA AFRICA AND SOCRASYNC JV SUPPORT FUNCTIONS
TYAS support functions at Head Office will assist the Project in meeting the Employer’s
requirements for the Project. Assistance is provided by the Financial, Commercial (Legal),
HR, IT, SHEQ, Methods / Estimating, and Plant on a direct support and ad hoc basis.
The functions below are only indicative of the departments’ role toward the Project.
4. PROJECT CONTROL AND DATA PACKS
4.1 Documentation Control

TYAS Reference Documentation: GSP 001 Document Control
Protection of Project Records
TYAS Reference Documentation: GSP 002 Records, SCP 101 List of Management
Standard Forms, PRP 001 Project Record Procedure.
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To ensure protection of manual / hard copy generated records, critical records will be
duplicated (e.g. client records) and stored on a remote server, password protected, and
password issued to a second person under the control of the QA Clerk / Document Controller.
The PRP 001 (Project Record Procedure) identifies records; responsibilities; retention and
client records.
A comprehensive register of the following documents but not limited to will be kept on site:
 Compensation Events (CE’s);
 Project Manager Instructions (PMI’s);
 Document Register;
 Transmittal Records Register;
 Data Pack Register;
 FEQ Register;
 Method Statement Register;
 QCP Register;
 EWC’s – Early Warning Register;
 FIR Register;
 NCRs;
 CAR/PAR Register
 Client Complaints;
Process control of documents include, Issuing of requests to Client, confirmation of

attendance, Inspection Detail, signature & approval and document distribution.
Document Control
All documents will be controlled by the JV Doc Control Officer. Document controller will only
manage documents and distribute to those who need to use the information. Documents must
be transmitted to Doc Control, electronically. Doc Control will then print, copy and distribute
the relevant document to relevant recipients. The Electronic and Hard copies are kept as part
of the Data Packs.
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Control of documents
Documents will be controlled through the process of formal submission and distribution
through the doc control system. If a document is replaced or superseded, it will be removed
from the file, stamped and placed in redundant document file. See also the document control
registers. Latest revisions of all documents shall always be available on site at the point of use
.
Control of Records
The Document Controller shall be responsible for the control of records. All documents, as
listed above, and all other documents will be recorded in Document Control Register and a
Document Distribution Register. The Document Control Register include the number,
description, originator, discipline, recipient & control dates and must be updated daily.
The Document Distribution Register include the document number, description, distribution
list, distribution date, the document revision number and a record of the collection of previous
revisions and superseding procedure. This register is also updated daily. Both registers must
be cross referenced with each other daily for control purposes and include distribution to the
Client and JV Management.
A remote server shall be used as a backup for all records. This server will be encrypted with
passwords to limit access from unauthorised persons. All hard copies shall be handed over to
the client on completion of the project, and soft copies shall be retained for a period of 5 years
after project completion.
After the retention period has lapsed, the soft shall be shredded using a specialised & secure
data wipe programme while all hard copies shall be shredded fiscally.
Management of Data Packs

TYAS Reference Documentation: SCP Preparation of Data Books,
The final repository for all Data Packs, as defined in the Data Dossier, will be available at the
QA Clerk / Document Controller on site.
One set of Data Packs will be handed over to the Employer on completion of the contract.
The Data Pack Register will include, but not be limited to the following;
 Communication; including Files referenced to Client, External and Internal
Communications;
 Commercial (Legal); including Contracts and Amendments;
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 Standard Forms Control; including Files for FEQ’s, EWC, CE’s, PMI’s, NCR’s and Site
Instructions;
 Quality; Including Project Quality Plan, Quality Management Policy, Review Meetings
records and Audit reports;
 Health & Safety; including Training, Management and Inspections;
 Environmental; including Training, Management and Inspections;
 SD; including Contractual arrangements, HR, Sub-contracting and IR;
 Technical; including Main Disciplines, Method Statements and Quantity Measurement

for BOQ; Main Disciplines will include, Earthworks, Concrete, Masonry, Waterproofing,
Roof Covering, Carpentry, Ceilings, Floor Coverings and Tiling, Ironmongery and
Metalwork, Plastering, Painting and Paperhanging, Furniture, Signage, Fire Protection,
Electrical Work, Mechanical Work, Glazing, External Works and lastly, Provisional
Sums;
 Financial; including Costing, Quantity Surveying, Works Progress Measurement and
Certification;
 As-Built’s;
Documents Control Numbering System
Reference Document ISO 9001:2008, ISO 9001:2015 and QA DATA Dossier – Annexure
C
TYAS is in the process of appointing a Document Control Clerk (DCC). The DCC will build on
the current numbering and Control system and formally submit the document control plan, as
and when changes are affected, to TGC.
Numbering will encompass the project number, Data Pack indexes, File Reference numbers,
Section number, document number and revision number. The QA Dossier and the Data Pack
Indexes are live documents and will be updated on a monthly basis.
Standard control documents, including FEQ’s, EWC’s, CE’s etc. will be numbered on same
system as above but must start at 01 and continue ascending in order.
The same applies to Contractor/Client transmittals.
4.2 Project Quality Management and Delivery

TYAS Reference Documentation: GST 003 - Project Delivery, GCP 006 - Corrective
Action Request Procedures
TYAS will carry out construction and installation activities under controlled conditions by
implementing the applicable site-specific procedures and method statements which specify
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work methods, sequence of operations, type of equipment and, where required, special
working measures.
The Quality Control Plans (QCP’s) will specify which sequence or item is to be inspected and
will set out the applicable accepted/rejected criteria. The content of the QCP’s will be agreed
on in conjunction with the Construction Manager & TGC Quality Manager. Improvement or
variation requests will be implemented by means Corrective Action Request Procedure (GCP
006) to correct deficiencies and the control of non-conformances. A PAR and/or a CAR will be
issued immediately on the discovery of any deviation from the drawings, specifications or
additional activities in the Scope of Works. A CAR and PAR register will be kept and updated
weekly and distributed to all relevant recipients.
TYAS is required to provide certain permits, licences and approvals prior to commencement of
the works. Enough time must be allowed in the programme for obtaining these.
4.3 Design Coordination (Refer to GST 001 Design Control)
No work will be done until the Request for information and / or CAR has been approved by the
client’s representative (Project Manager / Supervisor). Any designs that are to be undertaken
and completed by the JV must be approved through the CAR process, prior to any work
commencement.
4.4 Project Quality Assurance and ISO 9001
4.4.1 Roles & Responsibilities
Construction Manager (CM)
The Construction Manager reports directly to the Contract Director and is responsible for:
 Is overall responsible for the QA System (ISO 9001 and QAL STD 001)
 Project co-ordination with respect to forward planning, manpower allocation, plant
utilisation, cost control, quantity surveying and engineering support where required.
 Establish, ensure, maintain and monitor SHEQ requirements in terms of legislation,
project specific requirements and company policies.
 Establish and maintain a competent staff complement according to the site organisation
structure and the responsibility pertaining to the respective position.
 Establish the contracts contractual and overall program.
 Profit Management: i.e. Daily/weekly/ monthly Cost Control.
 Ensure that the detailed programs sub-contractors comply and adhere to the contractual
program.
 Managing, monitoring and ensuring that the works remains on programme, and that all
contractual dates are met.
 Managing, monitoring and ensuring that the contracts budget is maintained; controlled
and meets the targets set out in the objective.
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 Ensuring and maintaining agreeable relationships with the professional team.

 Ensuring that all contractual matters are administered in accordance to the conditions of
the contract.
 Establish and monitor the implementation of guidelines for the contract that reflects and
adheres to company policies and procedures.
 Review requirements, approve and where necessary re-arrange or re-allocate, source or
remove from site staff, plant, materials or sub-contractor service on an ongoing basis in
order to maintain a balanced and productive contract.
 Team Excellence: i.e. ensure people are adequately qualified; identify training needs,
performance appraisals, Industrial Relations management and management of
employment equity.
Project Quality Manager (PQM)

The Quality Manager perform all control functions, pertaining to Total Site accountability and
Control, as follows;
 Site Controlled Testing;
 Laboratory Controlled Testing;
 Technical and Inspection Control;
 Data Packs Control and Protection.
 Supervises Quality Control functions/activities of the project
 Support Construction Manager in dealing with the Client for all the Quality matters
 Allocates Quality Control personnel to the various areas of site activity
 Assesses the implementation of the Quality Plan and Quality Control Plans on the site
 Supervises inspections, reports and the documentation issued by inspectors and collect
and file the required Quality Records
 Supports and participate to all the internal/external audits
 Supervises the correct equipment calibration management activities
Clerk and Document Controller (DCC)

The QA Clerk and Document Controller reports directly to the Quality Manager and his / her
duties are as follow:
 Distribution / Issuing and management of all project documentation.
 Responsible for filing all documents & records
 Responsible for filing and maintaining data packs on the work site (Inspection & Test
control, Site Instructions, Method Statements etc.)
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 Liaison with Subcontractors and Client’s Personnel

 Collection and verification of Foremen daily Time sheets and cost allocation
 Control & Maintain IMTE calibration documents & register
 QA document management (listing, issue & control)
Senior Foreman (Including Foremen)
Senior Foreman reports directly to the Construction Manager. Foremen reports to the Senior
Foreman
 Inspection of materials received
 Supervision of the works (process control)
 Responsible for the quality of the works
 Traceability of all inspections
 Undertake work according to Site / Work Instruction Documents
 On-going checking of the quality of the workmanship
 Notify the Contracts Manager of product non-conformances
 Inspection of the work before covering up (closing with shutters, concrete, etc.)
 Safeguarding of Inspection measuring and testing equipment (IMTE) under his/her
responsibility
 Verification of accuracy of instrumentation
 Comply with the OHS Act, Act 85 of 1993 and Construction Regulations of 18 July 2003
 Setting out; tracing the shapes/ positions & dimensions of the works
 Checking and verifying works already set out
 Checking of the works
 Maintain beacons and control on site
 Aiding and working with the Assistant Construction Manager in establishing, managing
and maintaining a competent labour complement
ISO 9001:2008, ISO 9001:2015 Control and Reference; Quality Checklist
TYAS will use ISO 9001 as the basis of all Quality Control and manufacturing control.
The following main ISO 9001 Checklists will be employed:
 Control of Measuring and Testing Equipment

 Internal Audit Checklist
 Gap Analysis Checklist
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 Work Instruction Templates

 Product Realization & Planning Process
 Calibration Process
 Customer/Client Satisfaction Process
 Customer/Client Feedback & Complaints Process
 Manufacturing Specifications Control
 Reporting and Document Control Processes
 Project Progress and Review Procedures
 Project Quality Control Procedures
5. SITE QUALITY INSPECTION AND CONTROL
5.1 Project Quality Control Plan

A Project Quality Control Plan will be compiled for each activity and a register will be
updated and kept of all QCP’s. New QCP’s will be constantly adapted as Site conditions
and Scope of Works change. All aspects of this Project Quality will be controlled through
the quality control Plan. All aspects of management, technical and contractual will also be
controlled through the control plan. The PQCP also bears reference to the QCP’s and
Method Statements and will control issuing and approval of all documents pertaining to
control of the project. All control parameters will be incorporated into the Control plan and
controlled on approved parameters as registered and defined in terms of the classification
of Hold, Verification, Inspection and Approval.
5.2 Project Method Statements

Reference Documents MS-Ref-OOO, as per Method Statement register, attached as
Annexure D.
Every discipline and activity on construction must be reflected in a Method Statement. The
method statement must fully describe the process of construction, as well as the testing
and quality control processes. The relevant QCP will specify Quality Control, Testing
Parameters and Inspection Processes.
Method Statements will be submitted to the Client prior to Construction activities
commencement.
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5.3 QCP’s
Reference Documents QCP-Ref-OOO, as per QCP register, attached as Annexure E.
With reference to the PQCP, all work activity inception and execution control will be
compiled and submitted by the Quality manager (QM), prior to construction work starting
on specific designated construction discipline. The QM will then compile the relevant QCP
to align construction with the Method Statement and Quality Assurance.
5.4 FIC’s and FIR’s

Reference Documents FIC-Ref-OOO, as per FIC register.
With reference to the QCP’s, all work activity inspection control will be programmed and
submitted by the Quality Manager to TGC, as per the required notification standards of
ISO 9001 and QAL-STD-001. Prior to construction work starting, the Quality Manager will,
on a monthly basis submit a FIC schedule to TGC for review, control and planning. All
visual verification tests and witness events will be confirmed three days before test or site
inspection, through a FIR submission. The FIC register will be controlled, verified,
approved and submitted at the end of each month. After each inspection, the signed
inspection form, indicating process control and approval, will be submitted to the Client
through Document Control.
5.5 Auditing
Reference Documents AUD-Ref-OOO, as per Audit register.
Reference to item 1.5
The Audit Schedule is attached as Annexure B. This document will remain unchanged,
unless the dates on the attached schedule have changed and communicate to the relevant
personnel. This will ensure that all relevant personnel are informed timeously regarding
Audit dates and that all Audits are executed as per Planned Schedule.
5.6 SD Procedures
All procedures regarding Supplier Appointments, Database, HR and IR will be defined in the
SD Plan as submitted and approved by TGC. Local employment specifications and SMME
adaptation and procurement are specified through affirmative action and employment policies.
5.7 Subcontractor Coordination

TYAS Reference Documentation: GCP 007 Sub-Contractor Control
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The Contracts Manager / QS will ensure that the list of “Project Sub-contractors” (SFD 0701 or
similar) is completed and a copy is forwarded to the QA Clerk / Document Controller who will
file it accordingly.
Nominated subcontractors will be assessed by the Construction Manager and the results
forwarded to JV Head Office.
Approved sub-contractor interim performance appraisals will be done on the sub-contractors
by the Construction Manager three monthly. (SFD 0708) Final subcontractor performance
appraisals will be done at project completion.
Results of the sub-contractor performance will be communicated to the sub-contractor to
ensure continuous improvement and once signed off, will be submitted to TYAS Head Office
to ensure that the sub-contractor list remains updated.
All sub-contractors are required to submit their PQPs, Works Quality Plans/Method
Statements, H&S Plans and reference documentation to TYAS for submission to the
Construction Manager prior to works commencing. When the sub-contractor does not have
any Quality Control Procedures, they will be obliged to use the TYAS Quality System. All
relevant documentation will be submitted for approval prior to commencement of work, to the
Contracts Manager. We are in the process of identifying and approving sub-contractors
through the Resource Approval system of TGC. The list of Sub-contractors will be a live
document.
5.8 Inspection and Testing

5.8.1 Material
All material supplied shall be subjected to a Works Inspection Report In process inspection:
(SSP 008)
The Assistant Construction Manager will receive all test requests and record them in the
various test request registers (books).
The test request will then be numbered according to the correct work section. The Assistant
Construction Manager will distribute copies of these test requests to the relevant parties so
that the relevant inspections and tests can be carried out.
The following shall form part of the inspection/test report
 Project Title;
 Contractor and/or Supplier or Subcontractor name;
 Detail of test including reference to location, element, section, plant identified

under test;
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 Date, Time, Duration of test, weather conditions;
 Instrument used, serial number, calibration dates;
 Name and signature of those witnessing the test;
 ISO 9001 certification;
 Manufacturer guarantee;
Test results, with comparison to specified values or limits identifying non-compliances, where
relevant.
Inspection and Test Records will form part of the QA Data Dossier
Refer to the Project Inspection Flow Chart, Fig 8.5, below, for Inspection and Testing.
Further Reference to test processes and procedures is referred to in this section.
Material manufacturers will conform to ISO 9001 control standards and will be evaluated
according to the following;
 Material Specifications;
 Material delivery;
 Material Offload Procedures;
 Material storage procedures;
 Material certification;
 Material Manufacturing Specification conformance;

All Suppliers Certification will be submitted to TGC for approval prior to material being
delivered and delivery processes will conform to the Environmental and Health and Safety
Plans and Standards.
Material Control will form part of the Quality Control Data Pack.
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Inspection Flow Chart (Fig 8.5):
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5.8.2 Construction Manager/Assistant Construction Manager/Foreman will be responsible

for:
 The checking of the works and completion of the relevant check sheets;
 Tracing of shapes and setting out of structures with surveyor;
 Ensuring that inspection and testing are in accordance with the Project QCPs.
The results on the above-mentioned test requests are received by the Quality Manager and
attached to the original copy of the test request and presented to the TGC CM who will accept
or reject the results and sign off the documentation and the results will be recorded in the
register.
The Quality Manager will monitor and document trends and will present the findings during the
Project Meeting.
Materials and equipment that are manufactured off site will be inspected when required by
either qualified outside inspection agents or by TYAS QC Inspectors. Inspections are planned
and coordinated by the Quality Manager in conjunction with the respective Manager/s. TYAS
inspection and intervention points for subcontractors/suppliers, manufacturing plans and
controls, are implemented in accordance with Procedure GST 003 Project Delivery and GCP
007 - “Subcontractor Evaluation”.
5.9 Inspection, Measuring and Testing Equipment
TYAS Reference Documentation: GST 005 Calibration Testing Equipment, for a list of IMTE
used and calibration frequencies on this project refer to SFD 1202. This document
incorporates the expiry and recalibration dates of IMTE. The handheld tapes don’t require
IMTE control, as they are not critical for measurement control. The Construction Manager will
manage all IMTE.
All subcontractors will be responsible for the calibration of their measuring and monitoring
equipment. Copies of these certificates must be filed in the relevant Data Pack. Once
calibration certificates have expired, equipment must be sent away for recalibration.
TYAS require all Testing Equipment to be Calibrated every twelve months unless otherwise
specified by the manufacturer. Relevant calibration certificates will form part of the quality
control data pack. Equipment not conforming will be moved off site for re-calibration or
replacement.
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6. APPROVED INSPECTION AUTHORITY

The Approved Inspection Authority shall be subject to approval by the Employer’s Quality
Manager.
There will be a container on site with minimal laboratory facilities. Most of the tests will be
conducted off site at the nominated laboratory or on site by the Approved Laboratory Services
Provider, using their own Equipment for Testing. All Equipment are controlled by the Site
Quality processes.
Test equipment will have the correct calibration certificates to ensure that the test results are
accurate. Copies of these certificates must be filed in the relevant Data Pack.
The schedule of tests and inspections will be agreed with the Supervisor prior to start of
construction.
A copy of all test requests will be submitted to Head Office for information only.
6.1 Stores / Protection of the Works (Handling, Packaging, Storage and Delivery)
TYAS Reference Documentation: SCP 109 Stores Operational Procedure
TYAS shall take measures necessary for the protection from damage, dust and adverse
weather conditions of any structures and services.
TYAS is to ensure adequate protection, storage and/or stacking of materials that will be
utilised in the Works to ensure that no damaged materials are being used in the Works.
6.2 Special Processes and Procedures
The Quality Manager will notify the Client one month in advance prior to the conduction of any
special processes and procedures. This includes specific cold (simulated) or hot (Live) testing,
including compression, pressure, resistance and circuit resistive loss testing on electrical
network, mechanical installation and cold testing on water and sewer networks. All tests will
be incorporated into the FIC register.
6.3 Material Specifications, Traceability and Certification
All materials used on site must go through a process of verification. This include;
 Supplier Certification and ISO conformance;
 Transport and Delivery Control; including special procedures;
 Offloading Control, including special procedures;
 Storage Control, including special procedures;
 Installation parameters and Manual specifications;

All material control certificates will form part of the Material Control Data Pack
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6.4 Non-conformance, FEQ’s, Concessions, Early Warnings and CE’s

The standard control forms and any other control forms identified during the implementation of
the contract will be strictly controlled according to the NEC contract. The sequence of
processes generally complies to a re-action sequence of submittal in the following order; FEQ,
EWC, CE. The total time frame allowed for the submission of a CE is eight weeks. Non
-conformance reports or NCR’s is managed through a separate process.
The contractor must consider the specified timeframes in accordance with the NEC contract. It
is also essential that the Risk Reduction Meetings take place within the designated timeframe.
The risk reduction meetings are essential in resolving CE’s and are conducive to project
relations. NCR’s will also be controlled through a register and separate Data file.
6.5 Project Specific Support Functions
Quality Training and Implementation
Training needs are identified, as and when required, during the contract period according to
the project requirements.
Competence of personnel shall be evaluated, which will be carried out by the Quality
Manager.
The Quality Manager must ensure that training of personnel, about process control on site,
does occur.
Training of the TYAS Company Management System will be done as per site specific training
needs analysis.
7. PROCESS REVIEW AND IMPROVEMENT
7.1 Monitoring and Measuring

TYAS Reference Documentation: CSP 013 Monitoring and Measuring
Monitoring and Measurement form an integral part of the TYAS Management System and a
critical part of the main business process.
The following parameters are monitored through the conduction of TYAS SHEQ Internal
Audits:
 Environmental Parameters monitored through the Environmental Management
Plan requirements;
 Occupational Health and Safety Parameters monitored through Health and

Safety Management Plan requirements
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 Quality Product / Service conformity Parameters monitored through PQP

requirements.
TYAS has compiled a JV Quality Audit Schedule which identifies months in which audits will
be conducted to ensure that TYAS complies with all ISO requirements. This schedule
considers all Project and Head Office Support Functions. Schedule is included in item 5.5
above.
Quality review and improvement also are agenda items on all Point, Technical and Project
meetings. Every review and process, controls and increase effectiveness of Quality control.
7.2 Product Non-conformances

TYAS Reference Documentation: GCP 006 Corrective Action Request Procedure, GCP
005 Product Non-conformance Control
The purpose of identification of product or activity non-conformance is to ensure that products
and activities which do not conform to the requirements are identified, rectified and re-tested
to prevent unintended use or delivery.
All products will be monitored by the Construction Manager and the relevant production
managers/foremen in conjunction with the relevant QCPs. Any defects identified will be dealt
with as a non-conformance and the cause of the defect will be investigated. Construction
Manager and Foremen will review the product non-conformances/site instructions for possible
trends to initiate corrective and/or preventive action.
The Construction Manager is also responsible for the maintenance of a Site Instruction Status
List (SFD 0335) and or a CAR/PAR register, on product non-conformances.
CAR and PAR status list will be reviewed / analysed on a monthly basis by the Construction
Manager for any trends.
As and when a trend or concern is identified it will be controlled as defined in GCP 006
Corrective Action Request Procedure.
Summary of technical problems will be documented in the Point meeting (Refer to GCP 003
Project Review). Defects will be classified at the point meetings as either critical or non-
critical, depending on programme influence and timeline for conformance.
Close out defects will be done by section and sections on the critical path will be dealt with
immediately. Noncritical defects that do not affect the function of a section will be carried out
within a time frame agreed with the Client.
All defects will be recorded by means of a CAR and actioned according to recommendations
by the Construction Manager. Weekly meetings with Construction Manager and
Subcontractors and will be held to review status of CAR’s.
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On completion of the defects or outstanding works, the individual CAR Notices will be signed
off.
7.3 Corrective Action Request and Reporting
TYAS Reference Documentation: GCP 006 Corrective Action Procedure
Corrective Action is controlled as follows:
 The Construction Manager will control and maintain the status list on the non-
conformances (system and product);
 The Construction Manager will ensure the effective closure of Corrective Action
Requests (CAR) within the stipulated time frame, as stipulated by the client.
7.4 Service and Maintenance Plan

TYAS will provide Service & Maintenance Plan (SMP) relating to the completed works.
The Service and Maintenance Plan will include all necessary parts and operating manuals
from the Electrical and Mechanical Sub-contractors.
The SMP will be issued for use before handover.
8. QA DATA DOSSIER
The Quality Assurance Dossier, indicating relevant planned Data Packs are included as
Annexure C.
This is a live document that will be updated on a monthly basis. This dossier form an integral
part of the Data Pack Control System and are further expanded to the Data Pack
Register/Index.
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9. Annexure A: Project Organogram
Annexure A
Project Organogram
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10. Annexure B: Audit Date Control Schedule
Annexure B
Audit Schedule
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Date Site Audit Internal Audit External Audit TGC Audit
27 APRIL 2020 X TBA
26 MAY 2020 X TBA
30 JUNE 2020 X TBA
28 JULY 2020 X TBA
25 AUGUST 2020 X TBA
29 SEPTEMBER 2020 X X X TBA
Final Review Final Review Final Review Final Review Final Review
30 SEPTEMBER 2021 Retention Retention Rev Retention Rev Retention Rev

Rev
11. Annexure C: Quality Assurance DATA Dossier
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Annexure C
Quality Assurance DATA Dossier
Data Book (File 1) (CLIENT) 20 As Built Records
Index / Contents Page 21 Annexures

1 Approved PQP 21.1 Quality Policy
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2 Method Statements 21.2 ISO 9001
3 Project Organogram 21.3 Audit Schedule
4 Key Personnel Roles & Responsibilities Section QCP (File 2) (CLIENT)
5 Site Access Certificates Index / Contents Page
6 Summary of Scope of works 1 Approved QCP’s
7 Quality Control Plans – (Refer to file no.2) 2
7.1 Quality Activities and processes 3
7.2 Field Inspection Checklists 4
7.3 Site Quality Records/Test Results 5

8 Drawing Register 6
9 Electrical Certificates of Compliance (COC’s) 7
10 Field Engineering Queries FEQ’S – (Refer to file 8

no.3)
11 Non-conformances/Corrective Actions 9
12 Concessions Section FEQ’s (File 3) (CLIENT)
13 Inspection, Measuring and Test Equipment (IMTE) Refer to file no. 3 for Index / Contents Page
14 External Quality Audits Section General File (File 4)
15 Internal Quality Audits Index / Contents Page
17 NEC Defect Certificate 1 SHERQ Kick – Off Meeting
18 Punch List 2 Quarterly SHEQ Evaluation Report
19 Completion / Take over Certificates 3 List of Subcontractors
20 Limits of Authority & Specimen Signatures Section Layer works (File 9)

21 Concrete Mix Design Index / Contents Page
22 Project Record Procedure 1 Test & Inspection Request Book
23 Mill Certificates 2 Material acceptance/ Test

Certificates
Section Minutes (File 5) 3 Density Test
Index / Contents Page 4 Survey Records (Levels)
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1 External Minutes 5 Check Sheets

2 Internal Minutes Section
Section Index / Contents Page

Index / Contents Page 1 Test & Inspection Request Book
1 Test & Inspection Request Book 2 Material acceptance
2 Material acceptance 3 Density Test
3 Density Test 4 Survey Records (Levels)
4 Survey Records (Levels) 5 Check Sheets
5 Check Sheets Section
Section Index / Contents Page
Index / Contents Page 1
1 Test & Inspection Request Book 2
2 Pre & Post concrete inspection 3
3 Cube test results 4
4 Survey Records (Levels) 5
Section Etc/……
Index / Contents Page

1 Test & Inspection Request Book
2 Material acceptance/ Test Certificates
3 Density Test
4 Survey Records (Levels)
5 Check Sheets
12. Annexure D: Method Statement Register
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Annexure D
Method Statement Register
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13. Annexure E: QCP Register
Annexure E
QCP Register
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DATE: 31/07/2019

TORO YA AFRICA AND SOCRASYNC JV

DOCUMENT TYPE AND TITLE

PROJECT QUALITY PLAN

CONSTRUCTION OF EAST BANK ENTRANCE FACILITY AT THE PORT OF NGQURA

DOCUMENT CONTROL NUMBER

Company no Contract no Discipline Originator Revision

PROJECT START DATE PROJECT COMPLETION DATE

PREPARED REVIEWED REVIEWED APPROVED

ASSISTANT PROJECT QUALITY MANAGER CONSTRUCTION PROJECT MANAGER

ACC Accounts GFR General Foreman

CRD Contracts Director FRM Foreman

CC Cost Controller QAM JV Quality & Assurance Manager

CEO Chief Executive Officer HRM HR Manager

CFO Chief Financial Officer QS Quantity Surveyor

CM Construction Manager SUR Surveyor

PP Project Planner PM Plant Manager

COO Chief Operations Officer SCC Site Cost Controller

PQM Project Quality Manager SCL Site Clerk

HSM Health & Safety Manager QCC Quality Control Clerk

DSO Designated Environmental Officer

SDO Supplier Development Officer

DOC Document Controller

DSM Design Manager

ECO Environmental Controlling Officer

ACM Assistant Construction Manager

BLD Building Works FIN Finance

BOD Basis of Design ORG Organisation

CIV Civil Works QAS Quality Assurance

CMS Company Management System QCO Quality Control

ENV Environment SHE Safety, Health and Environment

CSP Company System Procedure REG Register

DWG Drawing SCH Schedule

MOU Memorandum of Understanding SCP Supplementary Company Procedure

MS Method Statement SFD Standard Form Document

OCP Operational Control Procedure SMP Service and Maintenance Plans

OMD Operational Management Document SSP Site Supplementary Procedure

PQP Project Quality Plan WDP Works Design Plan

PRG Programme WQP Works Quality Plan

QCP Quality Control Plan PQCP Project Quality Control Plan

GST General Site Transmittal GCP General Site Procedure

PSS Supervisory Satisfaction Survey CSS Client Satisfaction Survey

PAR Preventive Action Request

Reference Documents: Influence:

ISO 9001: 2008 & ISO 9001:2015 Reference and Control

Tender Documents Reference

Contract Documents NEC 3 Control

Company Policies and JV Contractual Documents Reference

SANS Schedules Control

Figure 1: INTEGRATED PQP SYSTEM DIAGRAM

TORO YA AFRICA AND SOCRASYNC JV Reference documentation: Project Quality

1.3 Project Description

TYAS manages risks at both a project and operational level.

 Contractual and Commercial;

JV and Site SHEQ Internal and External Audits

Project Manager / Supervisor (PSS) Satisfaction Survey:

2. COMMUNICATION and DOCUMENT DISTRIBUTION and CONTROL

TYAS Reference Documentation: Internal Communications / NEC Core Clauses

TYAS Reference Documentation: OCP Project Review and Estimating

Point Meeting 20% TBC

4.1 Documentation Control

 Project Manager Instructions (PMI’s);

 Transmittal Records Register;