Pakpattan Canal Rehabilitation Contract Quality Assurance Plan

Contract: PCSBIP/ICB-01
Rehabilitation and Upgrading of Pakpattan

Canal,
Khadir Branch and Pakpattan Islam Link
CONTENTS
1
Quality Assurance Plan..........................................................................................1

1.1
Preface............................................................................................................2
1.2
Quality Management Concept.........................................................................2
1.3
Organizational Approach.................................................................................2
1.4
Preliminary Quality Control and Assurance....................................................2
1.5
QA/QC Approach during Construction............................................................3
1.6
Quality Inspection Plan....................................................................................3
1.6.1
Types of Material Tests.............................................................................3
1.6.2
Earthwork..................................................................................................4
1.6.3
CONCRETE WORK.................................................................................6
1.6.4
Stone Pitching and Stone apron...............................................................8
1.6.5
BRICKWORK..........................................................................................10
1.6.6
Concrete Lining.......................................................................................11
1.7
TESTING ARRANGEMENTS / EQUIPMENTS............................................12
1.7.1
Testing at Construction Site....................................................................12
1.7.2
Testing in the Contractor's Field Laboratory...........................................13
1.7.3
Testing from External Laboratory............................................................13
QUALITY ASSURANCE / QUALITY CONTROL PLAN
Page 1
Canal,
1.
Quality Assurance Plan

1.1
Preface
This document details JV commitment and plan to ensure project deliverables to the
parties in a systematic and planned manner as per company management, experience,
policies, systems and in accordance with standard procedure to fulfill the requirements of
project specifications to the satisfaction of the Engineer and Client. The quality plan and
related documents are established on the basis of organizational and professional
experience of working in similar kind of project.
1.2
Quality Management Concept
With the firm having well defined quality objectives, the Quality Management for the
assignment shall therefore be at forefront, in strict adherence to the firms goal of
providing quality service.
1.3
Organizational Approach
The quality objective shall be broken down and the quality responsibility for each working
group and personnel involved will be defined respectively. All the staff specified in
different sub-organizations in the organization chart, the Project Manager and the
working group at all level, such as working groups for procurement, survey and setting
out, team members of construction groups, and the laboratory group for various tests,
and the Equipment & Plant maintenance group to ensure the equipment and plant being
in good working condition and the professional quality inspectors etc. All these personnel
involved, will be aware of their quality responsibility.
The management representative shall establish, improve and implement the Quality
management system for the project. Project Manager being the Head of QA/QC and HSE
is responsible for the Quality Control and Assurance of work.
1.4
Preliminary Quality Control and Assurance
The preliminary quality control of work will be carried out mainly for:
Work Method Statement Review
Career Trainings for Operational Personnel
Page 2
Canal,
QA/QC and HSE orientation for understanding of technical requirements of

different processes and work Instructions for the Operational Personnel
Source Approval and Material Test
Equipment selection, Check and Performance Test
1.5
QA/QC Approach during Construction
The In-process Control and Assurance for the work will be carried out mainly by:
1.6
Material samples at required frequency to ensure that the material is complied with
the requirements in the Technical Specification
Field Test will be carried out at a frequency no less than the requirement in the
Specification
The equipment/plants performance will be checked through routine checking and

when defect not been expected appears.
Conduct Self Check, Operational Personnels Mutual Check and quality

inspectors Final Check during construction process
In case of defect was found after the work has been done, remedy measures will
be carried out to achieve the quality required. If the remedy works are not
satisfactory, reconstruction for the defect area will be required
Quality Inspection Plan
Quality Inspection Plan is the document that describes the surveillance of all the
stakeholders involved in inspection and testing activities.
Inspection and test co-ordination and interfaces of all parties involved are defined and
implemented through QIP as a guiding document for QA/QC activities. QA/QC team
prepare QIP to ensure and monitor the conformity of all activities to the required
standards and specifications as mentioned in the contract. In-charge QA/QC checks and
reviews this QIP before submitting to the Engineer for approval.
The project core team as well as Head Office QA/QC functionaries gauge implementation
effectiveness of QIP, and deficiencies are highlighted to the project team for corrective
and preventive actions.
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Canal,
QA/QC team for final quality dossier submission as referred in QIP maintains all
Inspections and Test records on approved formats.
1.6.1 Types of Material Tests

The Quality Control/Quality Assurance tests are of three types i.e.
Tests to be performed at site
These tests are field specific and include the following:
Field Density Tests for compaction control.
Slump test for concrete.
Gradation Analysis of concrete aggregates i.e. sands and coarse aggregates.
1. Tests to be performed at Contractor's Field Laboratory

The tests to be performed at Contractors Field Laboratory include the following:
Soil classification Tests
Compaction Tests
Gradation Analysis of Aggregates.
Casting of concrete cubes/cylinders for compressive Strength Tests.
28 days compressive Strength Tests on concrete cubes/cylinders.
Sulphate Soundness of Aggregates
2. Test to be performed at external laboratories

These tests can only be performed in specified off-site laboratories and include tests on
reinforcing steel, abrasion and any other tests required during any problem or dispute.
1.6.2 Earthwork
Objective
Objective of this Section is to provide the recommended guidelines, sequential inspection
procedures and other relevant information to the field staff for their guidance in
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Canal,
performing quality assurance of earthwork for structures and for the canal embankments
etc. pertaining to the permanent works, being executed by the Contractor.
Applicability
This Section covers the open cut/foundation excavations, foundation backfills for the
structures and earthwork for irrigation canal embankments. The recommended guidelines
can also be used for other similar works and earthwork required for diversion
arrangements.
Construction Equipment
Selection of type of excavation and compaction equipment is with the Contractor. The
field engineers can check that the selected equipment is capable and adequate to
perform the required earthwork and advise the Contractor for any changes in equipment.
The following equipment will be deployed as per the nature of work involved;
Excavators
Tractors with implements
Front End Loaders
Dump Trucks
Motor Graders
Water Bowser
Dewatering Arrangements
Compactors(Rollers)
Inspection
Setting out details on site as per design will be the responsibility of the Contractor's field
staff. The Consultant's through their field staff shall check the setting-out accuracy, survey
control for NSL and design levels by joint survey with Contractor. These surveys will be
carried out by Contractor's surveyors in the presence of Consultant's Inspectors. The site
inspector shall monitor the excavation slopes for stability and compaction of the sub
grade and fills, etc.
If the Contractor encounters wet or slush, he is required to report to the Consultant's Site
Engineer who will jointly inspect the site, evaluate according to Earthwork submit their
recommendations for approval by the Engineer.
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Canal,
The Control of moisture and compaction of soils in the embankment of canals and
compacted earth consists of inspection of the material used, checking the amount and
uniformity of the soil moisture, maintaining the thickness of layer, and finally determining
the percentage of relative Dry Density of the compacted fill.
The relative Dry Density of the compacted fill is determined on the basis of Field Density
Tests and the Reference Laboratory Compaction Tests. The Field Density Tests will be
performed by the Contractor's staff under supervision of supervisory staff and when
directed by the Engineer In-charge or Site Inspectors.
The Modified Proctor Compaction Tests will be used as Reference Laboratory Tests for
fine grained silt clayey soils. These tests shall be performed at the Contractor s Field
Laboratory under supervision of Engineer.
The Maximum and Minimum Dry Density Test results (from external laboratory) are used
Reference Laboratory Tests for cohesion less sandy soils.
A good bond between the foundation and first layer of fill is achieved by scarifying and
moistening the foundation rather than using a very wet embankment layer
An important function of inspection is to determine when and where to make Field
Density Tests. These tests would be made in areas where degree of compaction is
doubtful.
Areas of doubtful density are sometimes detected by observation. Possible locations of
insufficient compaction include:
The Junction between areas of mechanical tamping and rolled earth fill
Embankment along abutments or cut-off walls.
Area where rollers turn during rolling operations.
Areas where too thick a layer is being compacted.
Areas where improper moisture content exists in the soil.
Areas where less than specified number of roller passes were made.
Areas where oversized rock which has been overlooked, is contained in the fill
Areas containing material differing substantially from the average.
Page 6
Canal,
Frequency of Control Tests

The recommended tests, their procedures, frequency and the required facilities for an
effective quality control/assurance of earthwork will be as specified. The field tests will be
performed in the presence of the site Inspector and the results recorded immediately on
completion of the test, duly signed by the authorized representative of the Contractor and
Consultants.
1.6.3 CONCRETE WORK
Objective
Objective of this section is to provide the recommended guidelines, sequential inspection
procedures and other relevant information to the field staff of the Contractor for their
guidance in quality assurance of reinforced concrete pertaining to the permanent works
being executed by the Contractor
Applicability
This section covers Plain Cement Concrete ( P.C . C.) the Reinforced Cement Concrete
(R.C.C.) works for permanent structures and monitoring facilities as shown on the
drawings and as directed by the engineer.
The Resident Engineer will leave the final selection t o the Contractor, but he can ensure
that the equipment is adequate to perform the concrete work.
Inspection
For quality assurance of construction activities the Contractor's Supervisory Staff will
proceed in accordance with "Checklist for concrete work".
For effective Quality Control, the Contractor will perform certain tests at different stages
of the concreting process. These tests include tests to be performed on concrete
ingredients, before start of the concreting works, tests to be performed during
construction stages and the tests t o be performed subsequently in the Contractor's Field
Lab under supervision of supervisory staff or in any other approved external laboratory
Consultant's Engineer can ensure that the required tests are performed by the Contractor
are in accordance with the specified procedures.
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Canal,
Concrete mix design will be carried-out at Contractors Laboratory or by a reliable

approved external laboratory using cement, sand and aggregates from the approved
source of supply and meeting the requirement of Technical Specification
The concrete mix design for each class of concrete in addition to mix proportion will also
provide water-cement ratio by weight (exclusive of water absorbed by the aggregate)
which will be determined on the basis of producing concrete having suitable workability,
density, permeability, durability and the required strength.
Concrete Pour Authorization

The contractor will submit two copies in two different colours (white and pink) of Concrete
Authorization (CPA) Request before starting concrete any component of a structure.
Contractor Engineer will check all the terns, before starting pouring of concrete. In case
of deficiency, he will be responsible t o rectify that deficiency. Pink copy will be provided
to Engineer for reference record. Contractor copy (white) will be kept at site by the
Contractor.
1.6.4 Stone Pitching and Stone apron

Objective
Objective of this Section is to provide the scope of applicability of the recommended
guidelines, sequential inspection procedures and other relevant information to the field
staff of the contractor, for their guidance in performing quality assurance of stone pitching
and stone apron to the Permanent Work, being executed by the Contractor.
Applicability
This Section covers the placing of stone pitching and stone apron at the specified
locations as shown on the drawings. The recommended guidelines can also be used for
similar works elsewhere in the project, as directed by the Engineer.
The equipment specified in the contract Specifications are only to provide guideline to
assist the Contractor in the selection of proper equipment. The Resident Engineer can
Page 8
Canal,
leave the final selection to the contractor. The Contractor may deploy the following
equipment.
Excavators
Dozer and Rippers
Front End Loaders
Dump Trucks
Dewatering arrangements
Inspection
For Quality Assurance (QA) of Construction activities the Contractors Supervisory Staff
will proceed in accordance with "Checklist for Stone Pitching & Stone Apron".
Base Filter Layer under Stone Pitching will consist of well graded material as specified in
BOQ and shown on the Drawings. The Stores individually shall weigh as specified.
All interstices in Stone Pitching/Apron will be well filled with rock Spalls. The rock Spall
will be rock fragments size between 2 inches and 4 inches.
The surface over which the base filter is to be placed will be trimmed to the proper lines
and grades and will be moistened with water and tamped or rolled with suitable tools or
equipment for the purpose of forming a firm foundation. Wherever over-excavation occurs
it will be backfilled with specially compacted fill. The base filter layer will be placed to a
uniform thickness and finished to reasonably smooth and even surface.
Stone used in the Stone Pitching/Apron will be clean rough quarry stone and will be
essentially free from dust, clay, vegetative matter and other deleterious materials. The
stone will be hard, tough, durable, dense, resistant to the action of water and air, and
suitable in all respects for the purpose intended. The stones will be hand packed and
placed and bedded in such a manner that the completed stone pitching is stable and
without tendency to slide.
Construction of stone pitching will commence at the lowest part of each structure or
section of a structure or canal and continue progressively upward. The stones, largest of
which will be used at the bottom, will be well bedded on a layer of Graded Granular
Material. In general the size of the stone used will have its major dimension the depth of
the specified pitching. Large open spaces between the stone will be avoided. Stone shall
be placed so as not to project above neat lines shown on the drawings.
Page 9
Canal,
Quality of Stone
While performing control over procurement and placement of stone and filter material, the
following characteristics of stone and filter material from the specifications will be
observed.
The loss in Los Angles Abrasion Test for large size Aggregates (ASTM-C535) will not
exceed 10% by weight at 200 revolutions or 40% by weight at 1000 revolutions.
The loss in Los Angles Test for small size Aggregates (ASTM-C131-81) will not exceed
10% by weight at 100 revolutions or 40% by weight at 500 revolutions
Test Procedures Frequency and Facilities
The recommended test procedures their frequency and required facilities for an effective
quality control of stone pitching and stone apron are presented in QAP/Stone/Test
Procedures.
1.6.5 BRICKWORK
Objective
procedures and other relevant information to the field staff of the contractor.) for their
guidance in performing Quality Assurance of Brickworks for Structures pertaining to the
Permanent Works, being executed by the Contractor.
Applicability
This Section covers the construction of Brickworks for brick masonry and brick lining for
various Structures, being executed by the Contractor.
The Contractor's field staff will take appropriate action as recommended in the checklist
before starting.
Quality of Bricks
The bricks will be regular, uniform in shape and size.
Bricks over-burnt, under burnt and irregular will not be used.
All bricks in oven-dried condition will not absorb more than one sixth of its weight when
soaked for one hour in water at 70 F to 80 F and will show no efflorescence on
subsequent drying.
Page 10
Canal,
The average compressive strength of five (5) representative bricks should not be less
than 2,000 lbs/in2 when tested in accordance with ASTM.C-67.
Each finished brick will be of standard size (9" x 4.5" x 3") first class and between seven
(7) and nine (9) pounds.
All brick will have a frog. 0.25peep on upper face.
Each brick for lining should have standard size (9x 4.5 x 3") first class.
Mortar Composition
Mortar for all brickwork will have mix ratio as specified in BOQ and sufficient water to
produce the proper consistency.
Mortar Sand
Mortar Sand will be as per specifications of sand for concrete works.
Water
The water used for preparation of/mortar will be free from objectionable quantities of silt,
organic matter alkali, salts and other impurities.
1.6.6 Concrete Lining
Objective
procedures and other relevant information to the field staff of the contractor for their
guidance in performing quality assurance of Concrete Lining.
Applicability
This Section covers the Concrete lining for various canals, being executed by the
contractor.
Construction Plant
The Resident Engineer can leave the choice of the construction plant and temporary
works for the Concrete lining to the contractor.
Inspection
Page 11
Canal,
For Quality Assurance of Concrete Lining construction activities, the Contractor's

Supervisory
Staff
will
precede
in
accordance
with
Checklist for concrete Lining".
A layer of cement sand mortar pad 1.5-1/2 Ratio 1:6 thick shall be placed over properly
moistened surface over bed, slopes prior to placing of concrete lining.
All the material used in concrete shall be accordance with the standards and specification
given in the section 9 concrete.
Concrete slump shall be in the range of 2-3 inch.
The compressive cylinder strength of the concrete (28 days) shall be 3000 Psi and
concrete will be cured properly by application of water.
Nominal maximum size of aggregate for concrete lining shall be and inches.
The concrete lining shall be divided into panels by control joints. Concrete shall be placed
in alternate panels.
The maximum dimension of any panel along the canal shall be 10ft. Each panel will be
accordingly separate from adjoin panels by transverse control joints. Each extended
across the canal in a straight line at right angles to the canal axis. The panel joint will be
laid over concrete profile 6"(width) x 4-1/2"(depth).
In the canal a bed width of less the 8 ft there shall be no longitudinal control joint and
each panel shall extend across the full section of canal including slop area.
In the canal a bed width more the 8 ft. there shall be 2 longitudinal control joints and the
full width of canal will be therefore 3concrete panels between any 2 transverse control
joints
The longitudinal control joints shall be located in the bed of the canal, distance 2-4 inches
from the nominal lines where the canal bed surface meets the side slope surface.
Concrete in the lining shall be placed to line and level by means of beams or roller
spanning the width of the panel its ends resting on. and sliding or rolling along the shutter
or the concrete surface on adjoin panel already concreted.
At intervals of 100ft. along the canal a transverse control joint shall be constructed as an
expansion joint.
No groove shall be formed in either concrete panel i.e. the joint will be open to the
bottom. A compressible filler % inches thick of bituminous and sawdust in ratio 1:2:2 shall
be provided between two adjacent concrete panels after 7 days.
The joint shall be sealed after thorough cleaning after a lap of 7 days.
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Canal,
1.7
TESTING ARRANGEMENTS / EQUIPMENTS
1.7.1 Testing at Construction Site

The Contractor for an individual contract package will be responsible for providing the
equipment and carrying out these tests under the direct supervision and guidance of the
Consultant's (LBDC) supervision staff
The contractor will provide and readily make available at construction site the following
equipment,
Earthwork:
Sand - Cone Density Apparatus, complete with base plate and sand bottle.
Density - Core Cutter 4 dia, complete with collar and hammer.
Speedy Moisture Tester capacity 20.0 gm. Moisture range 0 - 20% complete with
electronic balance and plastic carrying case.
Balance Triple Beam 2610 gm capacity with readability of 0.10 gm.
Concrete Work:
Cylinder moulds for concrete 6" dia. Complete with tamping rod (5/8"
long) and mallet.
Slump Test Equipment - complete with tamping rod 5/8" dia and 24" long.
Curing Tanks - These has been constructed close to the construction site for
storing concrete cylinders till their transportation to the Contractor's Laboratory.
Thermometer - to check weather and concrete temperature.
dia. 24"
1.7.2 Testing in the Contractor's Field Laboratory

Contractor shall established material testing laboratory at site, equipped and adequately
staffed to carry out the field laboratory tests as per requirements defined in the Contract.
This Field Laboratory established by the contractor and supervised by the Consultant's
Quality Control / Assurance staff will carry out the required tests and maintain a
systematic and retrievable record.
All Quality Control/Quality Assurance tests specified will be performed in the field
laboratory will be carried at the designated Field Laboratory at site.
Page 13
Canal,
The Contractor's will be responsible for providing and transporting the test specimens to
the laboratory under the guidance and supervision of the Consultant's Resident Engineer.
The contractors will bear the cost of these tests as per rate list available at any Field or
external Laboratory specified by the Engineer
1.7.3 Testing from External Laboratory
The Quality Control/Quality Assurance tests shall be carried out from an external
laboratory defined above recommended will be carried at following or any laboratory
specified by the Engineer
Central Material Testing Laboratory (CMTL) WAPDA Lahore.
University of Engineering & Technology Lahore.
Punjab University (Environment and Soil College).
PCSIR Laboratories Lahore and Karachi.
Cement Research & Development institute Kot Lakhpat, Lahore.
Pakistan Standard and Quality Control authority. In PITAC Compound, Lahore.
Page 14

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Contract: PCSBIP/ICB-01

Rehabilitation and Upgrading of Pakpattan

Quality Assurance Plan..........................................................................................1

Quality Management Concept.........................................................................2

Preliminary Quality Control and Assurance....................................................2

QA/QC Approach during Construction............................................................3

Quality Inspection Plan....................................................................................3

Types of Material Tests.............................................................................3

Stone Pitching and Stone apron...............................................................8

TESTING ARRANGEMENTS / EQUIPMENTS............................................12

Testing at Construction Site....................................................................12

Testing in the Contractor's Field Laboratory...........................................13

Testing from External Laboratory............................................................13

QUALITY ASSURANCE / QUALITY CONTROL PLAN

Quality Assurance Plan

Quality Management Concept

Preliminary Quality Control and Assurance

Work Method Statement Review

Career Trainings for Operational Personnel

QUALITY ASSURANCE / QUALITY CONTROL PLAN

QA/QC and HSE orientation for understanding of technical requirements of

Source Approval and Material Test

Equipment selection, Check and Performance Test

QA/QC Approach during Construction

The equipment/plants performance will be checked through routine checking and

Conduct Self Check, Operational Personnels Mutual Check and quality

QUALITY ASSURANCE / QUALITY CONTROL PLAN

1.6.1 Types of Material Tests

Slump test for concrete.

Gradation Analysis of concrete aggregates i.e. sands and coarse aggregates.

1. Tests to be performed at Contractor's Field Laboratory

Soil classification Tests

Gradation Analysis of Aggregates.

Casting of concrete cubes/cylinders for compressive Strength Tests.

28 days compressive Strength Tests on concrete cubes/cylinders.

Sulphate Soundness of Aggregates

2. Test to be performed at external laboratories

Tractors with implements

Front End Loaders

QUALITY ASSURANCE / QUALITY CONTROL PLAN

Embankment along abutments or cut-off walls.

Area where rollers turn during rolling operations.

Areas where too thick a layer is being compacted.

Areas where improper moisture content exists in the soil.

Areas containing material differing substantially from the average.

QUALITY ASSURANCE / QUALITY CONTROL PLAN

Frequency of Control Tests

QUALITY ASSURANCE / QUALITY CONTROL PLAN

Concrete mix design will be carried-out at Contractors Laboratory or by a reliable

Concrete Pour Authorization

1.6.4 Stone Pitching and Stone apron

QUALITY ASSURANCE / QUALITY CONTROL PLAN

Dozer and Rippers

Front End Loaders

QUALITY ASSURANCE / QUALITY CONTROL PLAN

For Quality Assurance of Concrete Lining construction activities, the Contractor's

QUALITY ASSURANCE / QUALITY CONTROL PLAN

TESTING ARRANGEMENTS / EQUIPMENTS

1.7.1 Testing at Construction Site

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

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

Thermometer - to check weather and concrete temperature.

1.7.2 Testing in the Contractor's Field Laboratory