Presentation Outline

Definition of Quality, Quality Control and Quality Assurance Elements of Quality Control System Control of Materials Control of Works and Processes Inspection and Testing Control of Non Conforming Products Control of QC Records Conclusions
Language of Presentation English
Naw Raj Bhatta (MEng., FIE, MIGS, MIRC, cE)

What is Quality ?
Quality mean different to different people Adequate strength Functional need Adequate durability

Meaning of Quality To Enduser

Smooth and comfortable riding surface (i.e., pot hole free safe road)

Meaning of Quality to Us
Compliance to specified requirements : Materials Process Equipment/ Workmanship End Specifications
Summarizing - Achievement of desirable functions & performance within allowable tolerances

HOW TO ACHIEVE QUALITY ?

No Royal Road to Quality Achievement !! Sincerity of Desire & Change in Attitude and Skills
Quality Interested Client Group Quality Interested Engineering Group Quality Interested Construction Group People Produce Quality Works, Rather than Inspection & Records Per Se
BUT

Quality workmanship in Engineering, Procurement and Construction

Inspection, at Best , Can Only Detects Poor Work

Changing People is NOT Easy

So ! Pending larger issue of changing people, some form of Control is indispensable

What is Quality Control ?

1.
Quality control is a structured mechanism (operational procedures & controls) to verify and ensure the compliance of:
Materials Works & Processes Equipment, Workmanship End results
to pre-set requirements

2. Control of Non-Conforming Products

3. Control of Records
4. Accepting or rejecting the work
For ISO Definition

What is Quality Assurance ?

Def.n - All planned & systematic activities implemented within Quality System to provide confidence that quality product will be achieved. QA gives confidence to the owner that works executed will meet the intended requirements of quality. It ensures orderly work culture & minimize wastage and rejection.

COST OF QUALITY
1.5 to 2 % of construction cost Set the quality standard at optimum level

Cost Per Unit of Highway Element

Minimum Total Cost Improved quality construction cost + maintenance cost

Cost of improved quality construction

Maintenance & failure correction Total Cost

Quality Level

ELEMENTS OF QC / QA SYSTEM
Quality Assurance / Quality Control System
End Product Road with Desired Riding Quality over the Design Life

Design
Thickness Choice of Materials Specifications

Construction
Materials Control Process / Works Control Inspection & Testing Control of Non-Conformance

Maintenance
Maintenance Strategy Routine & Periodic Inspection

Acceptance Criteria

Quality Records

Routine & Periodic Maintenance

Maintenance Standards
QS-Req.

QA/QC measures are both organizational & Technical

Quality Control of Materials

Materials
1. Natural Materials Soil, Gravels, Aggregates, Pond ash etc.

2. Manufactured Materials Cement, Steel, Bitumen, Construction Chemicals

3. Designed BC, DBM, Concrete Mixes, WMM etc.

Statement of Purpose
The objectives should be:
To ensure that the materials used on the project meet the project specifications and expectations To ensure accountability and conformance of the materialsthat the materials used are fully traceable.
No materials shall be used without approval

Elements of Materials Control

Source Screening & Approval Materials Approval Control of Materials on Site Certification of Materials by Manufacturer Testing of Materials at Site Laboratory Supervision of Testing Quality Records

Control of Materials of Natural Origin

Source Screening & Approval Process

Control of Manufactured Materials

Source Screening & Approval Process
1. Contractor identifies the material (s) required for the project 2. Contractor develops his list of proposed Suppliers 3. Contractor obtains all necessary information from the Supplier consistent with the projects screening requirements 4. Contractor submits his proposed Supplier for Engineers review 5. Engineer reviews Contractors submittal. Advises Contractor if additional information is needed 6. Engineer indicates his approval (no objections) of the source to Contractor if appropriate, else, 7. Engineer advises that the Supplier is unacceptable 8. All approvals subject to supply of material in accordance with project specifications.

Quality Control of Materials (Contd)

Materials Approval Procedure
1. The Contractor draws up a Material Approval Request form giving adequate notice to the Engineer to arrange suitable inspection and test. 2. The Engineer inspects and witnesses testing of the material in accordance with all relevant codes, standards, specifications and regulations applying. 3. The Engineer may request further information from the Contractor before inspection and test can be completed. On successful completion of the

inspection and test, the Contractor will be given approval. On approval, the
Contractor and Engineer will jointly sign the form for approval, stating any further conditions applying. 4. If the material is rejected for any reason, the field engineer (s) will clearly state the reasons for rejection on the form. The form is to be passed to the RE for subsequent attention. 5. All materials approved must be physically identifiable and traceable at all

times.

Quality Control of Materials (Contd)

Control of Materials on Site
1. 2. Advance copy of the mill certificate indicating compliance to quality On arrival at site- the Contractor make out a priority Request for Inspection

3.
4.

A Material On Site Form must be attached with RFI

Challan (Bill of Loading), Mill Test Certificates etc. in the drivers possession shall be obtained.

5. 6.

Joint inspection to identify lot/batch/heat number. Confirmation that the materials are suitably marked and identifiable (Materials w/o identification tags will be rejected / or quarantined)

7.

Check and verify the test results indicated in the Certificates

8.
9.

If Materials is judged in conformance, the material will be unloaded

Take material samples for mandatory control testing, audit etc.

10. Store the material appropriately at approved storage area 11. Move the material to worksite with proper Material Transfer Note

Quality Control of Works

Quality Control Plan
Define objectives clearly

Enumerate activities involved

Go 2 list

Prepare a detailed construction methodology to be followed

Prescribe requirements of quality in each activity

Lay down surveillance plan, inspection procedures and check-list for each activity

Design, use and maintain appropriate data formats &

reports for the execution of each activity

Quality Control of Works

Operating Procedure
Contractor submits a formal request for inspection (RFI/RAC) whenever a quality controlled task is completed. A permission to proceed sheet is attached. The Engineers Representative will arrange inspection of works to be carried out on a routine basis. He will depute Field Engineer (s) to supervise particular task (s). Upon receipt of RFI, Field Engineer (s) will inspect the assigned work (s). With the help of check list and his experience, he will assess whether the Contractor is executing the works in accordance with the contract and sound engineering practice. The Contractor will test in accordance with the specifications, under the guidance of the Engineer, all works. In the event that the work, or part of the work, does not meet the specifications or quality standards in accordance with the contract, the Engineer may give the contractor an opportunity to rectify the work. The work must again be inspected/ tested and on acceptance may be approved on the request for approval on completion.

Inspection & Test Plan

Typical Example

Inspection & Test Plan

Typical Example

Inspection Check List

Inspection Check List

Permission to Proceed (PTP)

Hyderabad Outer Ring Road Contract Package .

Permission to Proceed for GSB-D Course

PTP No.______________
It is requested that the following subgrade section be released for construction of the GSB-D.

Station: km ___________ to km ___________

Carriageway
Contractor:

Left

Right

By this request, we acknowledge that we have constructed the subgrade in accordance with the contract specifications. The following items have been checked by our staff and found to be in accordance with the project design and specification. Item Subgrade width Design Cross-fall Tolerances on Elevation Subgrade thickness Data and Comments

Field Relative compaction Materials

Contractor: _______________ Contractor Rep: _______________ Date: _______________

Engineer:
We have reviewed the contractor's submission and have carried out representative checks on the work. In our opinion, the contractor has carried out the work in overall accordance with the project specifications. We have no objections with the incorporation of the subgrade into the project works. The subgrade section, as noted above, is hereby released for GSB-D placement subject to the comments given below. Field Engineer
Date:

Survey:
Date:

RE
Date:

Conditions of this PTP and other Comments: 1 2

This PTP is effective for 2- days. If the GSB-D is not placed within this period, it will be necessary to a recheck of the subgrade condition. Any subgrade judged to have been damaged at any time prior to placement of the GSB-D shall be remediated by the contractor to the satisfaction of the Engineer at the contractor's cost in accordance with all contract stipulations.

Contract No:

_______________________

Location: __________________________ Request Approved:____________________

Testing Control
Range of Testing
1. Screening Test e.g. choosing a borrow area, aggregate source, cement .. 2. Control Tests e.g. testing of materials at frequency specified by the

contract
3. Audit Tests to verify independently the reported properties of the material 4. Tests for Design Mixes- to select appropriate mix design for concrete, bituminous mixes etc. 5. Acceptance Tests e.g., testing of cubes cast of the produced concrete to confirm the required strength is achieved and is

consistent
6. Special Testing, e.g., integrity test on telecom pipes, dynamic load tests on piles

Testing Control (Contd)

Quality Control in Testing 1. Establish Laboratory Work Procedures 2. Establish Laboratory Equipment Calibration Procedure 3. Establish Frequency of Sampling and Testing 4. Design Test Worksheet Formats and Summary Report Forms 5. Perform tests in accordance with specified test method (primarily IS methods) 6. Follow important quality checks for each test 7. Modification & New Test Procedure

Laboratory Work Procedures

Procedure for Sample Processing Procedure for the Registering and Handling of Samples in the Laboratory Procedure for Dealing with Third Party Testing Procedure for Recording, Reporting and Distribution of Test Results Procedure for Amending Reports Procedure for the Filling of Test Reports, Worksheets and Other Correspondence within the Laboratory Procedure for Measurement, Recording and Distribution of Metrological Readings Procedure for Random Sampling Procedure for Equipment Calibration (for each equipment)

Equipment Calibration Procedures

Establish calibration plan for various measuring equipment at project QC laboratory indicating frequency of calibration, method of calibration, accuracy required Maintain a indicating unique identification of the equipment and calibration status. Safeguard the devices against any adjustments that may invalidate the calibration status

Calibration Plan

Calibration Status

27

Control of Non-Conforming Products

Non Conformance can be in : Material Process

Equipment
Document Product

28

Control of Non-Conforming Products

Control of Non-Conformance will involve following steps : Identify & report discrepancy found in the process or activity or product Evaluate & review non-conformity

Review identical non-conformity if occurred

earlier & steps taken Seek expert advice, where appropriate Evaluate the cause, effect on final product, extent and severity

29

Control of Non-Conforming Products

Disposal of Non-Conforming Products Repair e.g., repair of narrow cracks in DBM by

fog seal
Re-work- e.g., scarification, watering and recompaction of sub-grade layer in which desired compaction level is not achieved (detected by field density testing)

Reject e.g., 28-days compressive strength of

concrete less than specified; CBR of compacted subgrade less than specified and so on

30

Control of Non-Conforming Products Closure of Non-Conformity After recommended actions are undertaken Re-testing indicate conformance

Records of Non Conforming products

Defect Report

Summary of NCRs

31

Typical Non Conformance Report (NCR)

Summary of Non-Conformance

Control of Quality Records

Requirements
All records required to demonstrate the effective operation of the system should be identified & maintained All records should be codified to ensure proper identification and traceability Appropriate format of measurements and reports should be proposed by the contractor & approved by the supervision consultant All quality records should be legible, readily identifiable and retrievable

Keep the quality records in secure conditions to avoid damage and deterioration
Establish Retention period of various quality records

Type of Records
Measurement and data sheets End-use reports

Type of Quality Records

Type of Quality Records

Type of Quality Records

Type of Quality Records

38

CONCLUSION
Quality can be attained through control Get it right first time Get it right second time Get it right every time

39

Thank You

ISO Definition of Quality Control

Quality Control consists of operational techniques and activities that are used to fulfill the requirements of quality. For example, by testing of random samples, an estimate of the quality of the product can be made.
For Highway Construction Project: Quality Control is defined as the procedure adopted and controls exercised to ensure that the materials proposed to be used in construction, processes adopted for construction and workmanship of construction conform to the prescribed standards and laid down acceptance criteria.

How QC needs & requirements are taken care of

In the contractual environments, needs / requirements are specified, and In other environments implied needs / requirements should be identified and defined.

Typical QC Steps

QC Vs QA

Typical QA Steps

QC Vs QA- Examples

Quality System Requirements ISO 9001

20 Elements:
Management Responsibility Quality system Contract Review Design Control Documentation and Data Control Purchasing Control of Customer Supplied Product Product Identification and Traceability Process Control Inspection and Testing Control Control of Inspection, Measuring and Testing Equipment Inspection and Test Status Control of Non Conforming Product Diagnostic & Corrective Action Handling, Storage, Packaging, Preservation and Delivery Control of Quality Records Internal Quality Audits Training Statistical Techniques

Elements of QA/QC

Material On Site Report

Material Transfer Report Material Transfer Report

Sample Check List (1)

SIEVE ANALYSIS Purpose : This procedure provides instructions to be gone through in carrying out
sieve analysis in the laboratory

Objective : To obtain reliable gradation of soil Procedure : IS :2720, part 4. The following items should be checked to ensure reliable
results.

Fine grained material disperse adequately in the wet Yes mechanical analysis ` Agglomeration of material break down into individual Yes grains Any loss of material during testing Overloading of sieves Broken or distorted sieve screens Adequate shaking of sieves
Yes Yes Yes Yes

No No No No No No

Sample Check List (2)

In-situ Density by Sand Cylinder Method Purpose : This procedure provides instructions to be gone through in carrying out insitu density test in the field Objective : To obtain reliable results of field density Procedure : IS :2720, part 28. The following items should be checked to ensure reliable
results. Use of proper calibrated sand Testing of appropriate soils Absence of protrusions, pockets, or overhangs in the hole Hole too small Proper calibration of sand cone Moisture in sand Densification of sand while filling the hole Yes Yes Yes Yes Yes Yes No No No No No No

Permission to Proceed (PTP)

List of Major Activities Requiring Segment Quality Plan

S.No. 1 2 3 4 Segment Description Earthwork in embankment/ subgrade / shoulder Construction of drainage layer / granular subbase Construction of wet mix macadam Construction of dense bituminous macadam/ bituminous concrete

5
6 7

Miscellaneous works : laying of kerb, rigid pavements, reinforced earth structures

Construction of cross drainage structures Construction of minor bridge /underpass
Construction of toll plaza and other buildings
Providing & fixing metal beam crash barriers Turfing, filter media and stone pitching

8
9 10

Acceptance Criteria (1)

Acceptance Criteria (2)

Typical Process Control Flow Chart Granular Subbase

Laboratory work Procedure

Inspection & Test Plans

Consider the following parameters for the preparation of Inspection & Test plan
1. 2. 3. 4. 5. 6. Type of product characteristic determines type of test / measurement Location of suitable measurement point in the realization process sequence Characteristics of the product to be measured at each point, and the documentation & acceptance criteria to be used Establish points of hold, witness, verification of selected characteristic of a product as required by project technical specifications Inspection & testing required to be performed by statutory / regulatory authorities Where, when and how to engage third parties to perform inspection & testing