QA System KMC AS7

Widening and strengthening of existing National Highway from 2
lane to 4 lane from km. 1040.300 to km. 1013.000 of NH-31 in

Assam on East-West corridor under phase - 2 programme of
NHDP Package no. EW - II (AS-7).
KMC CONSTRUCTIONS LIMITED
KMC/QAM/AS-7
DOCUMENT No.
0
REV No.
VINAY KUMAR UPADHYAY, (Senior Project Manager)

PREPARED BY:
Contract Package no. EW - II (AS-7)
APPROVED BY
DATE 31 May 2006

QUALITY ASSURANCE MANUAL
INDEX
Sl.No. Contents Page

No.
1 Purpose 6
2 Scope 6
3 Salient Features 7- 9
4 Terms and Definitions 9-10
5 Quality Assurance System 11-16
6 Documentation Requirements 17-20
7 Management Responsibility 21
8 Quality Policy 22
9 Responsibilities of key positions 23-26
10 Resource Management 27
11 Competence, awareness and training 28-29
12 Product Realization 30-31
13 Method Statement 32-52
14 Purchasing 53-56
15 Preservation of Product 57-58
16 Control of Monitoring And Measuring Devices 59
17 Internal Quality Audits 60-70
18 Records Control 71-74
Page 2 of 76
QUALITY MANAGEMENT SYSTEM MANUAL
FOREWORD
This Quality Assurance Manual is applicable for KMC
CONSTRUCTIONS LIMITED, for the Project ‘Widening and
strengthening of existing National Highway from 2 lane to 4 lane from
km. 1040.300 to km. 1013.000 of NH-31 in Assam on East-West
corridor under phase - 2 programme of NHDP Package no. EW - II
(AS-7) has been prepared as per the established, implemented and
certified Quality Management System (as per the requirements of EN
ISO 9002& EN ISO 9003 Standard).
Construction Methodologies and QA/QC Procedures / Inspection &

Test Plans etc. for all activities are included with this Project Quality
Plan for review and necessary approval from Client / Engineer.
Detailed Construction Methodology for some major activities will be
submitted at the time of execution.
All the necessary changes and comments, if any, by Client / Engineer

shall be incorporated in the subsequent revision of this Project
Quality Plan.
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REVISION RECORD SHEET
Sl. Reference Old Rev. New Rev. Detail of Revision

No No. & Date No & Date
Page 4 of 76
GLOSSARY
HQ - HEAD QUARTERS
QA - QUALITY ASSURANCE
QC - QUALITY CONTROL
QAM - QUALITY ASSURANCE MANUAL
ITP - INSPECTION AND TEST PLAN
PM - PROJECTS MANAGER
ME - MATERIALS ENGINEER
PE - PLANNING ENGINEER
SCI - SECTION INCHARGE
SI - SITE INCHARGE
NCR - NON-CONFORMITY REPORT
PA - PREVENTIVE ACTION
CA - CORRECTIVE ACTION
PO - PURCHASE ORDER
WO - WORK ORDER
MIS - MANAGEMENT INFORMATION SYSTEM
ACE - ACCEPTED COST ESTIMATE
JCR - JOB COST REPORT
P&M - PLANT & MACHINERY
S/C - SUB-CONTRACTOR
MTC - MANUFACTURER’S TEST CERTIFICATE
MRN - MATERIAL RECEIPT NOTE
Page 5 of 76
RFI - REQUEST FOR INSPECTION
TQ - TECHNICAL QUERRY
1.0 PURPOSE:
This Project Quality System manual is prepared and formulated as a Management Summary of Quality related
activities required to meet the terms of contract. This manual sets out the Management practices, describes the
Quality Management System of KMC CONSTRUCTIONS LIMITED.
Reference and Applicable Documents
The following documents are used as a source of reference for the preparation of this Quality Assurance Plan.
Drawings and specifications prepared by consultants.

Codes of practices as listed in drawing & specifications.
Construction Group Guide for Project Quality Plan.
Construction Group Work Procedures.
2.0 SCOPE:
The contents of this Quality Assurance Manual are applicable to Procurement, Construction, Inspection, Testing
and Commissioning works, that will be carried out by in connection with KMC CONSTRUCTIONS LIMITED
Widening and strengthening of existing National Highway from 2 lane to 4 lane from km. 1040.300 to
km. 1013.000 of NH-31 in Assam on East-West corridor under phase - 2 programme of NHDP Package
no. EW - II (AS-7). In preparation of this document, due regard has been paid to the requirements of EN ISO
9002& EN ISO 9003 Standard).
Major Activities in brief are:

 Mobilization of Equipment / Plant / Machinery and Manpower.
 Construction of Enabling Works.
 Setting up of Infrastructural facilities i.e., Offices, Camps, Plants etc.
 Survey and Setting Out Works.
 Selection of Various Construction Materials.
 Earthwork in Excavation & Backfilling Works.
 Embankment and Sub-grade Works.
 Granular Sub-base Works.
 Dry Lean Concrete and Pavement Quality Concrete for Rigid Pavements.
 Bituminous work for Flexible Pavements.
 Cross Drainage Works i.e. Slab / Pipe Culverts.
 Bored Cast-in-situ Piling Works for Bridge Foundations.
 Well Foundation Works for Bridge Works.
 Sub-Structure and Super Structure Works in Bridges.
 Pre-stressing Works for Bridge Girders.
 Drainage and Protection Works.
 Traffic Signs / Marking Works.
 Traffic Control Works during Construction.
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 Repair and Maintenance Works.

 Safety and Environmental Protection Measures.
 Other Miscellaneous & Provisional Item Works as per BOQ.
3. Salient Features
Project Description Widening and strengthening of existing National Highway from 2 lane to 4 lane from
KM 1040.300 to KM 1013.000 of Nalbari- Bijni Section of NH-31 in Assam on
East West Corridor under phase-II Programme of NHDP.
Length of Project Road From Patacharkuchi to Kaljar (Total 27.30 Kms)
Contract Package No. EW-II (AS-7)
Employer National Highways Authority of India.

Govt. of India.
Engineer BCEOM - STUP - AARVEE (JV)
Contractor KMC Constructions Ltd.
Contract Value 207.17 Crores INR (After rebate of 18.0% on the initial bid amount)
Date of Notification for

Commencement of Work 19th October '2005.
Date of Handover
of site 1st December' 2005.
Contract Period 30 months
New Carriageway 2 laned rigid pavements.
Existing carriageway 2 laned flexible pavements.
Major Bridge 1 No at KM 1025.500

2x 40.36 m; 81 m long.
R.O.B. 1 No at KM 1028.470
Main span - 66.679m , Viaducts (160+156)m and RERW approaches (270+327)m
Underpass 1 No at KM 1038.400
Main span - 8.3m, retaining walls (210+235)m
Realignment 3.0 KM
Page 7 of 76
Conditions of Contract FIDIC Conditions of Contract for works of Civil Engineering Construction,
Fourth Edition 1987, reprinted in 1992 and Conditions of Particular Application
Technical Specifications MOSRT&H Specifications for Road & Bridge Works

(Fourth Revision - 2001, Reprint - November 2002)
Performance Security 10% of the Contract Price
Dispute Settlement Disputes Review Board, Arbitration Process
Amount of Liquidated damage 1/2000 of contract price per day.
Limit Liquidated damage 10% of the Contract Price
Scope of Works (as per BOQ) :
Bill No 1 Site Clearance And Dismantling 2,417,024 INR

Bill No 2 Earthwork 164,993,840 INR
Bill No 3 Sub base, Base And Base Course 269,791,152 INR
Bill No 4 Bituminous Courses And Cement Concrete Pavement 757,144,925 INR
Bill No 5 Cross Drainage Works (Culverts) 130,300,091 INR
Bill No 6 New Bridges/ Underpasses/ Grade Separators / Robs / Flyovers 571,247,916 INR
Bill No 7 Rehabilitation of Bridges & Culverts 4,949,791 INR
Bill No 8 Drainage & Protective Works 62,566,057 INR
Bill No 9 Traffic Signs, Marking and Road Appurtenances / Others 51,306,539 INR
Bill No 10 Junctions 2,027,245 INR
Bill No 11 Miscellaneous 36,074,498 INR
Bill No 12 Miscellaneous of Road 18835547.6INR
Subtotals, Bills 1 to 12 2,071,654,626 INR
Major road work value (in lacks) Major road work value (in lacks)
BC 751.94 Excavation 185.98

BM 730.02 GSB 1835.64
C&G 5.90 PQC 3752.69
DBM 1456.01 SDBC 25.29
DLC 669.60 Subgrade 725.21
Embment. 567.15 WMM 861.00

New Reconstruction Rehabilitation Widening &
Construction Rehabilitation
(as per contract) :
Page 8 of 76
Hume Pipe Culvert - - - -
Box Culvert - - - -
Slab Culvert 8 8 - 14
Minor Bridges - - - 22
Major Bridges - - - 1
R.O.B 1 - - -
Underpass 1 - - -
Site Establishment
Regional Office GS Road, Cristan Basti, Guwahati-5, Assam.
Site Office Km 1034 on NH-31, C/o Mahananda Tahbildar, Word No. 4, Milanpur
Pathsala Town, Barpeta Dist, Assam.
Plant Area Km 1029.35 on NH-31, Bhukamari Daulatpur, Dist- Barpeta, Assam
Workshop Km 1029.35 on NH-31, Bhukamari Daulatpur, Dist- Barpeta, Assam
Store Km 1029.35 on NH-31, Bhukamari Daulatpur, Dist- Barpeta, Assam
Laboratory Km 1029.35 on NH-31, Bhukamari Daulatpur, Dist- Barpeta, Assam
Quarry & Crusher Km 1104 on NH-31, Dewduar, Assam
4.0 TERMS AND DEFINITIONS

In the context of this document, the following abbreviations or phrases shall have the meanings noted
against.
Client - NATIONAL HIGHWAY AUTHORITY OF INDIA

Consultant - BCEOM-STUP-AARVEE JV
Contractor - KMC CONSTRUCTIONS LIMITED
Sub-Contractor / Vendor – Any person, firm or Company appointed by the client directly or through
the Contractor to provide service.
Third party inspection – A service provided by any recognised independent agency employed by
the Client, or by the Contractor to oversee inspections and tests for materials whenever required by
the client or his representative.
Quality – Totality of Features and Characteristics of a product or service that relies on its ability to
satisfy stated or implied needs.
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Quality Assurance – All those planned and systematic actions necessary to provide adequate
confidence that a product or service will satisfy the given requirement for quality.
Quality Control – Operational techniques or activities (e.g. Inspection and Testing) used to verify
technical and quality requirement for services and or products.
Quality Audit – A systematic and independent examination to determine whether quality activities
and related results comply with planned requirements and whether these arrangements are
implemented effectively and are suitable to achieve the objectives.
Quality Plan – A document setting out specific practices, resources and sequence of activities
relevant to a particular material, procedure, service in a contract or project.
Procedure – A documented description of the method to be adopted in the performance of a given

task and where applicable, the acceptance / rejection criteria for that task.
Inspection – Activities such as Measuring, Examining, Testing, Gauging one or more characteristics
of a material, procedure, product or service and comparing this with the specified requirements.
Corrective Action – An activity, the intention of which, is to return the non-conforming item or action
to a stage of conformity. It also covers the action taken to prevent further recurrences of non-
conformity.
Concession – A formal approval by Client / Consultant to authorize a deviation from the specification
or design which does not effect the final function of the proposed design.
Hold Point – A stage in the production cycle when inspection and /or test are performed to determine
the acceptability of an item for further processing.
Witness point –A stage in the production cycle when a third party inspector, contractor or company
representative witness any inspection and or test to determine the acceptability of an item for further
processing.
Repair – The process of restoring a non-conforming condition such that the item conforms to the
original specified requirements, where such a repair or restoration is acceptable.
Calibration – The comparison of two instruments, measuring devices or gauges, one of which is of
known accuracy and where applicable, traceable to an internationally recognized standard.
Non-Destructive Examination – This means whereby the integrity or conformity of an item can be
assessed without resorting to destructive analytical procedures.
Check – A stage in the production cycle, when a third party Inspector or Contractor Representative
performs a check or test to determine the acceptability of the item for further processing.
Review – A stage in a construction cycle, when a third party Inspector or Contractor or Company
Representative may verify records and or procedures and determine the acceptability of the same.
Material Test Certificate – A document of test results either from source of materials or from in-
house or independent agencies
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5. QUALITY ASSURANCE SYSTEM

General Requirements:
In the changing scenario of globalization and economic liberalization, a great deal of emphasis is already laid
on development of infrastructure through construction of a dependable road network. Consequently,
consistency in the quality of road and incorporation of quality as major attribute in the organisation entrusted
with the task of road construction has assumed paramount importance.
Quality of a product or service has many aspects and that quality should conform to the customer’s
requirements has now become the focal point in managing quality in all organizations/ projects. Earlier, quality
was often considered as conformance to specifications particularly in the road sector and was based on
detection at the end of production stage, thus, ensuring conformance to specified requirements entirely through
inspection and testing of the product at the end. This was the quality control phase through which the road
construction industry has been traveling in the recent past.
If one looks around in the corporate sector, it is revealed that more conformity to specifications is no longer
considered as a measure of quality. Alternatively the major corporate organizations have switched to a Quality
Assurance (QA) phase. The QA stresses on planned and systematic working with a view to eliminate the
chances of non-conformities. Statistical process control techniques are employed to assure that the product
meets specified requirements, rather than achieving it through detection and rejection of defectives at the end
of production.
Need for a ‘Manual on Quality Assurance System’
In order to achieve the aim of building safe, serviceable, durable and economic highways, the road structure
should meet certain requirements. The characteristics that a structure should possess to fulfill these
requirements have to be specified. The codes of practice and the contract documents strive to achieve this by
way of defining design criteria, practical rules, technical specifications, testing and acceptance criteria and
workmanship. All these strategies implicitly depend upon human skills for their successful and reliable
application, which, eventually, determines the quality of highways. The basic desire to produce quality work is
essential in the mind of all those connected with road projects.
In order to achieve the required level of quality of the final product, as specified by engineering science, it is
necessary to have a strategy for management of human skills by way of Quality System defining quality policy,
quality assurance plan and quality audit. Apart from this, it is also necessary to explicitly define ‘Quality’ itself,
which is expected to be achieved through the Quality System.
General Approach
Concept
The term ‘Quality’ has been defined as the totality of features and characteristics of a product or services that
bear on its ability to satisfy stated or implied needs. In the contractual environments, needs/ requirements are
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specified. The code of practice endeavors to meet the requirements by a three-pronged strategy. Firstly, it
specifies the acceptable materials of construction outlining the various tests of acceptance; secondly, it defines
various design criteria, practical rules and sound engineering practices for guiding the designers in arriving at
appropriate structural solutions; and thirdly, it deals with the workmanship and other aspects of construction
which ensure that the design intents are realised in actual construction. The contract documents and technical
specifications define the inter-relation of various parties to the contract as well as the requirements of quality.
All these strategies implicitly depend upon human skill for their successful and reliable application. The total
system of policy, management responsibility, internal and external control, testing and quality control,
acceptance criteria, corrective action, and documentation is covered in the quality system. It also encompasses
the overall organisation structure, responsibilities, procedures and processes for implementing quality
management. The aspect of overall management function that determines the quality policy and implements it
by such means as quality planning, quality control and quality assurance within its quality system, is called
‘Quality Management’.
The quality of the product (or service) is ensured and maintained by following a documented ‘Quality
Assurance Plan’, which sets out specific quality practices, including ‘Quality Control’ which are operational
techniques of controlling quality. ‘Quality Assurance’ (QA) includes all those planned actions necessary to
provide adequate confidence that the product (or service) will meet the requirements, and is essentially a
system of planning, organising and controlling human skills to assure quality. Quality Assurance Plan sets out
planned actions required for quality assurance. This continuous monitoring and verification of the status of QA
activity to ensure that it is being followed is called ‘Quality Surveillance’. ‘Quality Policy’ is a formally
documented statement of management’s intentions and directions as regards to quality. ‘Quality Audit’ is a
managerial tool used for reviewing the whole or a part of the quality system by internal or external agencies not
connected with operation of QA plan. ‘Total Quality Management’ brings to these concepts a long-term
global management strategy to achieve and improve quality and calls for the participation of all members of the
organization for the benefit of the organization itself, its members, its customers and society as a whole.
Quality Assurance and Quality Assurance Manual
Quality Assurance (QA) is defined as all the planned and systematic activities implemented with the Quality
System and demonstrated as needed, to provide adequate confidence that an entity will fulfill the requirements.
A Quality Assurance Manual (QAM) provides a base document outlining policy, procedures, responsibilities,
compliance, acceptance criteria and documentation. It should be prepared and accepted by all parties
concerned before start of project.
It should generally cover the following:

(a) Identification of all parties involved in QA and their inter-relationship.
(b) Internal QA system of each party.
(c) Levels of cross-checking/ verification in case of multiple verifications/ controls, including system
of inspection and audit, wherever applicable.
(d) Organization of personnel, responsibilities and lines of reporting for QA purposes.
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(e) Criteria for acceptance/ rejection, including identification of proper authorities for such decisions.
(f) Inspection at the end of defect liability period.
(g) Items to be covered in maintenance manual.
(h) All formats for documentation.
Though, several parties may be involved in enforcing quality assurance for any particular item of work or a
product, the ultimate responsibility of compliance with QAM and of achieving required quality generally rests
with one party. When process and/ or product control is carried out by the contractor or his agent, it is termed
as internal control or ‘one level’ control. For important items of work, independent parallel checks/ supervision
are carried out by one or more agencies, either on full scale or on sample basis. This is normally carried out as
external control or second level control. In some cases, third level of control may also be required, such as,
that by a regulatory body or by insurance agency. These levels of control parties, their functions and inter-
relation between them should be clearly defined in the Quality Assurance Manual. The Manual also should
identify the responsible parties, their functions and inter-relations between them.
Quality Assurance Manual for Highways/ Roads
The owner, consultant, approving authority, main contractor, material suppliers, specialist/ nominated sub-
contractors, manufacturers of materials being incorporated in permanent works are the parties involved in the
overall QA system for road construction.
Typical organizational structure for various parties involved in design and construction (owners, consultants,
contractors) are given in Figs. 1, 2 & 3.
Various activities on a road project can be classified under three groups.
(1) Design
(2) Construction
(3) Manufacturing
In design activity, purchaser is the authority that places the order for design and/ or project preparation. It may
be either the owner of the road as in the case of preparation of detailed design, or the contractor, as in the case
of design and construct contracts. Supplier is the consultant who undertakes to prepare the design. The
design, drawings and tender documents are the end products. The QA manual should cover those
requirements of quality system, which concern services or expertise.
In construction activity, purchaser is the authority that places order for the construction of road. Supplier is the
contractor who constructs the road. In this case, the end product is the road.
Manufacturing activities fall under the following two categories.
The first category consists of factory-manufactured item for general use, like, aggregates, cement, bitumen/
bitumen products, reinforcements, etc.
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The requirements of quality system pertaining to the specifications of quality, testing and acceptance procedure,
procurement, storage, and such other relevant items, which are to be carried out by owner/ designer/
contractor, should be covered therein.
The second category of manufactured items cover road markers, lane dividers; lighting masts, tollbooth, road
signs, etc. manufactured by specialist suppliers and are purchased for use as finished products by the
contractor. The quality assurance manual should cover the quality assurance of such items.
Typical Quality Assurance Plan For Design And Construction

Introduction
Step by step procedures, which would help in achieving consistent and comprehensive methods of checking and
approval of works at every stage, need to be established and documented. These procedures should be
reviewed periodically, amended, as found necessary and revised documents prepared.
All parties involved in the QA plan should have their internal QA systems clearly defined in form of a specific
Quality Assurance Manual (QAM) for the respective purposes, such as, QAM for manufactured products (by the
manufacturers or suppliers). It is also necessary for owner/ purchaser to have his own internal QA plan. QAM for
highway project as a whole integrating all these plans shall be prepared/ or approved by the owner and/ or
approving authority, if any. Each vendor (i.e., supplier, designer, contractor, manufacturer) will thus, have his own
internal QA procedures that are required to be agreed upon, in advance, with the purchaser of the respective
activity.
As highway building in India is mostly undertaken by Govt. agencies, it is necessary that the contractor/ designer
obtain concurrence of their QAM from the concerned Government Department (‘Department’). The Guidelines
should be used by the respective parties in evolving of the operational QAM to be agreed between the contractor
and the Department for adoption at site.
Quality assurance plan for a road construction project, documented in quality assurance manual, would
essentially comprise the following aspects:
 Organization.
 Control of data documentation, both product (roads) related documents and quality related records
together with control documents.
 Q.A. procedure for setting out of works and temporary works.
 Control of materials.
 Traceability and product identification (if required by clients).
 Calibration.
 Control of workmanship aspects.
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 Protection during construction stage.
 Non-conforming products.
 Quality audit.
Organisation of the Contractor

In most of the cases, the management of the contractor shall be responsible for jointly reviewing the
requirements of the project with the owner and structuring the appropriate organisation for the same. This
project specific organisation is headed by Project Manager. The duties among the staff below him could be
generally on the following functional lines:
Planning Engineering
Covering all aspects of work planning, resource requirements of materials and labour, progress review and
internal interface activities.
Materials Engineering
In-charge of material management including procurement and quality control aspects, viz. inspection, field
sampling and testing.
Construction Engineering (No. as per requirement)
In-charge of various construction activities and responsible for following approved working methods, drawings and
specifications.
Plant, Equipment and Instrumentation Engineering
In-charge of deployment, operation, maintenance of various mechanical and electrical plant and equipment as
well as instrumentation needed at site for construction.
Service Engineering
In-charge of laying/ relocation of buried services along/ crossing the alignment.
Landscape Architecture
Will be generally involved at design stage and partly during construction stages.
Safety Engineering
Responsible for preparation and implementation of safety systems within the construction site in addition to
ensuring safety of Public/ Traffic using part of the roadway under construction.
Survey Engineering
Responsible for all topographic, land surveys and setting out of works as per drawings.
Quality Assurance Engineering
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Responsible for all aspects of preparation, review, acceptance of quality plan and operation of the same at site.
He is also in-charge of quality related records and documents.
Quality Auditing
Independent team reporting to management.
The duties of assisting engineers and supervisory staff at various levels should be clearly specified as are relevant
to the quality assurance systems, depending on the specific project requirements and size. The number of staff
doing various functions listed above can be increased/ decreased.
6. Documentation Requirements
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GENERAL
In KMC Constructions Limited the Quality control Manual, System Procedures, Work
Procedures, work instructions and formats are all part of this manual called as QUALITY
ASSURANCE MANUAL, which is specific to this project.
4.2.2 QUALITY MANUAL,
Step Procedure description Responsibility Reference Record / Record

No document / data Document distribution
1 Prepare project quality plan in line QA Engineer Contract Draft QAM
with the following. document,
Contract document ISO 9001,
National & International standards MOST, IS
codes
ASTM , BS &
AASHTO
2 Seek approval from client / QA Engineer Notes
engineer
3 Incorporate in QAM any QA Engineer QAM Retain Master
comments from client / engineer Copy with
& Get Approval duly Stamped as “ QA- site.
Master Copy ”
4 Issue applicable QAM Sections to QA Engineer Issue
sections in site, stamp as notes/
"controlled copy" and maintain RECORD
record of issue. CONTRO
L
4.2.3 CONTROL OF DOCUMENTS

No document / Document distributio
data n
DOCUMENT CHANGE
1 Receive inputs through QA Engineer MOM,
Management Review Meeting / Suggestion
Internal audits/ Customer notes from
suggestions / Document change customer.
note from Users
2 Review the requirement of QA Engineer Revised QAM
document change, revise
accordingly and send to Quality
Head for approval.
3 After approval, Effect the change QA Engineer Controlled copy To all
in Master copy & issue the Xerox List controlled
to all the Controlled copyholders. copy
holders
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4 Ensure superseded copies are QA Engineer SUPERSEEDED

destroyed in all sections except documents to be
QA master copy. preserved in
separate file
DATA CONTROL
5 Receive New drawings and enter Planning Drawings
in drawings register Engineer Register
6 Maintain drawing register Planning Drawings
including issue to users, stamp “ Engineer register
Master copy “for Planning office
Copy & “controlled copy “ For
Issues.
7 Stamp Superseded drawings Planning Superseded
and withdraw from use Engineer drawings file
8 Receive In Coming Mails & Affix Planning Incoming & out To
Date Of Receipt, Send To Engineer going register concerned
Concerned For Action Initiation
Through Project Manager,
Maintain Incoming & Out Going
Letters, Mails, Fax Register
Mentioning Subject And Date Of
Receipt & Action Taken
9 List out Codes and Standards QC/ Planning
and maintain at site, control Engineer
Technical Specification
10 Control All Circulars originated Planning Register
from Planning Section Engineer
11 Identify Files as applicable Respective File List
SHs KMC
12 Identify and maintain Receipt, Stores Store Records
storage and issue records Incharge
DATA CONTROL IN
ELECTRONIC MEDIA
13 Maintain a list of documents for All sections File list as per
data record in electronic media format
with backup detail for important
files as per users decision
14 Ensure storage & preservation of All sections File list as per
electronic media to avoid format
damage/deterioration
Protection of confidentiality
Data received through E-mail
15 Print out & retain file all data All sections Printed copies in
received from clients file.
consultants / government bodies
which may be of contractual
nature.
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Control of Records
Objective: To establish and maintain a system for control of Quality records
Scope: All records generated as a result of the documented Quality System
Step Procedure description Responsibility Reference Record Record

No document / distributio
data
n
1 Identify quality records All sections QAM All SICs
relevant to the section
2 Prepare master list of QA & Section Master list Section
quality records & Control incharges Quality Head
Record
3 Identify file with file number All sections

or format number/ Record
description, location, person
responsible Etc.
4 Ensure all records are All Sections
Legible
Not Tarnished
Easily Retrievable
Distributed to concerned
persons
Stored safely for the
required period
5 Once in Six months Record All sections
room is to be inspected to
check the following Physical
status, sign of deterioration,
Preventative action for safe
guarding the documents
and action on destroying of
documents.
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Record Control
All the records mentioned in Record Control List are controlled by QAE after approval by the Material
Engineer, the controlled copy shall be issued to the concern engineer or dept using record control
format.
A copy of the signed record control copy of each department has to be filed as maser list of quality
records.
Whenever document changes or revision is received issue the revised copy through record control.
In Management Review the change of document shall be decided after getting the feedback from
customer or site.
Amended drawing shall be kept with Drawing Amendment Sheet and the same shall be distributed to
the site. Superseded drawing shall be marked with superseded stamp and status shall be maintained
by entering in to Construction Drawing Status Register in the Technical Office.
QA Dept. is responsible to keep all controlled copies of enlisted records in the QAM. Whenever change
of record format will take place, the previous copy shall be taken back by QA Dept. and newly approve
controlled copy shall be issued after stamping. The previous copy shall be stamped as superseded and
filed
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7. Management Responsibility:
CUSTOMER FOCUS:
Objective: To establish and maintain a system for customer (client) orientation to identify
Customer needs & expectations and converting them into requirements to achieve
Customer satisfaction
Scope: Includes collecting Customer feedback and attending to Customer complaints and
taking necessary corrective and preventative action.
Ste Procedure description Responsib Reference Record Record

p ility document distributi
No / data on
1 Record the Customer Project Customer
complaint Manager complaint
register
2 Reply on Customer Project - CCR
complaints with action plan Manager
and target dates for
achieving the same, Within
4 days of receipt
3 Action taken on customer QA / CCR
complaint PLANNING
4 Discuss the Customer Project Complaint notes
complaint, examine root Manager letter/Action
causes. & Take preventive taken letter
measures. Procedure is to
be reviewed and
reformulated for prevention
of repetitive complaint .
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8. QUALITY POLICY
The Quality Policy of KMC Construction Limited is:
To Strive for Quality Excellence, in order to achieve Customer

Satisfaction by providing Goods and Services to the Standards set by
the Customer and to Contribute to increasing the Company’s
Competitiveness.
The Quality Objectives are :
1. Improving Customer Satisfaction.
2. Continual Improvement of the effective performance of the

Quality Management System of the “4-Laning & Strengthening of
NH-31” Project.
3. Continuous enhancement of the Quality of the Products of the

Project.
4. Timely completion of the Project.
5. Improving the capability of the Human Resources involved in the

Project.
6. Completion of the Project within the Project Budget.
7. Improving the Safety and Environmental Practices at various

operations of the Project to prevent any harm to workers,
Properties and Environment.
Page 22 of 76
9. Responsibilities of key positions in the context of

meeting Customer Requirements
Projects Manager:
 Responsible to Vice President (Operations)
 Responsible to exercise cost control, ensure compliance to meet time schedules,
compliance to Quality and Safety requirements for all operations of the Region.
 Responsible to the respective Business Unit head for acquiring orders and
satisfactory execution of all contract, from inception to final hand over to the Client.
Section Head (QA):

 Responsible to Project Manager.
 To Ensure preparation of ‘Quality Assurance Manual’
 To Review and approve ‘QAM. Effect amendments based on contractual and
execution requirements, specification Changes and Audit Reports.
 Ensure that personnel at site are trained to perform Quality Checks.
 To conduct Audit at sites as per Audit plan to verify conformation to QAM.
 Review conformance to QAM based on Audits. Interact with sites and record
necessary corrective action.
 Receive corrective action. Revisit site if necessary to ensure that corrective action is
satisfactory.
 Prepare MIS on Audit summary, pending NCR, Status of Major NCRs and action
plan for corrective action.
Quarry Manager
 Reports to Project Manager
 Responsible for obtaining necessary statutory & environmental clearances,
maintaining the same in accordance with Environmental Management Plan
 Responsible for Quarry & Crushing Operations,
 Responsible for daily planning, procurement, storage & optimum utilisation of
blasting Material.
 Responsible for allocation & transportation of boulders for crushing as agreed with
planning to the correct quantity & quality.
 Responsible for Proper Production & Stacking of crushed aggregates
Plant and Machinery Manager

 Reports to the Project Manager functionally.
 Co-ordinates with Planning Engineer for daily deployment of plant to various
sections (Planning Engineer allots to sections as per priority).
 Conducts all preventive maintenance as per equipment manuals.
 Ensures adequate stock of fast moving spares.
 Allots duty quota to Operators.
 Administrates fuel oil supply, reconciles usage in consultation with Stores
Department, submits reconciliation statements as on 25 th of each month to
Planning Department.
Page 23 of 76
 Conducts repairs, breakdown maintenance, arrange alternative

equipments when required economically.
QA Engineer:
 Responsible to the Section In charge administratively and functionally reporting
to the SH (QA).
 Responsible for preparation of quality plan, obtaining necessary approval from the
Customer as applicable and assist Section In charge in effective implementation
of approved quality plans and QC procedures.
 Responsible for communicating with all site staff about the QA requirements with
respect to the project.
 Responsible for Receiving and reviewing of all reports related to quality matters.
 Responsible for Co-ordinating for early disposal of non-conformity reports.
 Responsible for organising and conducting Quality audits with the co-ordination of
PE/CM/RE and planning engineer.
 Responsible to organise and to conduct Management Review Meeting at regular
intervals at site.
QC Engineer
 Responsible to the Section In charge administratively and functionally reporting
to the SH (QA).
 Responsible for material selection and mix combination to meet the
Specification requirements within the overall cost provisions
 Identifies all material requirement, sources.
 Conducts qualification tests for source approval.
 Conducts tests on materials as per Test and Inspection plan.
 Indents all laboratory equipment, commissions and conducts calibration
exercises as per plans.
 Documents all tests in standard formats.
 Liaison with external labs, third party agency labs.
 Conducts laboratory activities independently and reports any potential
problems to the Construction Manager.
Engineer - Safety
 Reports to Section In charge
 Prepares the project safety plan
 Investigate potentially unsafe acts, practices
 Investigates, reports unsafe occurrences and initiates preventive steps
Section In charge
 Reports to the Project Manager.
 Prepares daily plans of work from agreed weekly/monthly plans.
 Organizes manpower, materials, equipment to achieve plans.
 Complies to all procedures, drawings while execution (Project Quality

Plan)
 Checks all works done by subordinates.
Page 24 of 76
 Co-ordinates with other agencies when required.

 Ensures safety in the workplace as per Project Safety Plan.
 Inculcates good housekeeping practices.
 Prepares Sub-contractors bills in time and submits to the Billing Engineer.
 Affords all facilities to quality audits.
 Reports any errors to Construction Manager, endeavors to improve.
Section Engineer
 Reports to the Section In charge
 Checks all works done by subordinates and maintains check records
applicable to each activity.
 Ensures safety in the workplace as per Project Safety Plan.
 Inculcates good housekeeping practices.
 Reports any errors and endeavors to improve.
Surveyor:
 Responsible to the Section In charge / Planning Engineer.
 To prepare Survey Plan and obtain Client / Consultant Approval.
 To establish control points as per survey plan.
 Responsible for day to day survey activities and maintain records.
 To carryout post construction survey and record as built status.
 Conduct calibration of any survey equipment’s as per plan with QC Engineer.
Formworks Engineer:
 Reports to Section In charge.
 Preparation of Formwork program based on the overall construction program.
 Planning, Co-ordinating, finalising & implementation of Shuttering Scheme.
 Computation of Doka material requirement based on realistic program.
 Ensuring effective and proper utilisation of Shuttering / Staging materials for
particular type of Formwork.
 Educating Sub-contractors on System form work.
 Making mock-up of various system Formwork.
 Finalising rate of sub-contractors for various type of Formworks in consultation
with RE / Planning office.
 Periodical reconciliation of Formwork materials including plywood & Timbers.
Accounts and Administration Officer

 Responsible for Fund Management.
 Payments to suppliers and sub-contractors in time
 Collection of Customer outstanding.
 Book keeping and preparation of Cost Statements
 Ensure conformance to statutory regulations and filing returns.
 Responsible for Staff / labor welfare and general administration.
Store Keeper:
 Responsible to the site accountants and Planning Engineer.
 Receipts & issue of materials including client supplied material.
Page 25 of 76
 Arranging for inspection of incoming materials.

 Proper storage of materials.
 Ensure proper identification and traceability of materials
 Ensure proper Stock analysis and inventory control / documentation
 Responsible for updation of SMS
Time Keeper:
 Responsible to the site accountant and administrative officer
 Keep records of S/c workmen and departmental workmen.
 Maintain in and out time of S/c and departmental workmen.
 Prepare and send daily labor report to CM.
 Prepare bills effect payment of departmental workmen.
 Maintain records pertaining to labor as per statutory requirements.
 Responsible for upkeep of the labor colony and labor welfare facilities.
Page 26 of 76
10. Resources Management

General
Objective: To Establish and maintain a procedure for Resources in construction activities at

site.
Scope: This section proposes the methods adopted by the Project Manager that will enable
him administrate the resources to the satisfaction of the Clients and KMC Constructions
Limited.
The table here under describes activities, responsibility, frequency and records envisaged for
this procedure for internal administration.

No document tools distribution
1 Plan resource requirement for Planning Contract Schedules
staff,P&M, materials and labour Engineer document
to meet contractual
requirements.
2 Obtain approval for above from Planning Approval
engineer Engineer note on
schedules
3 Revisit schedules monthly PM Updated
intervals, revise when needed. schedules
Page 27 of 76
11. Competence, awareness and training:
Objective: To establish a procedure that prepares every employee individually and

collectively to contribute their full expertise and achieve goals according to priority and
availability
Scope: All employees at Project Level

Sl Record
No Procedure step Responsibility Document Record distribution
1 Identify training needs of employee. Project Training list
Recommend suitable in-house / Manager/ with names
external training. HRD
2 Follow training is completed and check Project Effectivenes
the effectiveness during process Manager/ s record with
HRD names
3 Pep talk on work procedures to skilled Project Training list
workmen like masons, carpenters, Manager /
fitters will be given in-house in regard SITE
to knowledge, competence in INCHARGE /
respective trades & the quality of end QA
product. INCHARGE
Infrastructure & Work environments.
Enclosed Sketch Shows The Logistic Plan, Site Offices, Work Places, Utilities, Quarry ,
Crusher , Batching Plats , Stores , Communication Towers Etc, Gives The Infrastructure
Provided At The Site To Achieve Continuous Connectivity , Less Lead Time & Conformity To
Requirements.
Page 28 of 76
TRAINING RECORDS
YEAR:……………… LOCATION:
……………………………….
Department/ Section: ……………………………
Sl Name of staff PS No Recommended Training done/ Remarks

No Training not done
.
Name :
Designation:
Page 29 of 76
12. Product Realization
Planning of Product Realization
Objective: To establish and maintain a procedure for planning and control of construction
activities at site.
Scope: This section proposes the methods adopted by the Project Manager that will enable
him administrate the Contract to the satisfaction of the Clients and KMC CONSTRUCTIONS
LIMITED Management. The table hereunder describes activities, responsibility, frequency and
records envisaged for this procedure for internal administration.
Sl. Activity Responsibility Responsib Date of Record

No. for preparation ility for preparation /
Review Review
1. Prepare Construction Planning Engineer Project Within 10 days Construction
Program & Schedules Manager from LOI program
2. Update construction Planning Engineer Project By first week of Construction
program every month, one Manager every month program
week before meeting with
clients.
4. Prepare List of Authorized Planning Engineer Project Within 30 days List of
Signatories Manager of job start Authorized
Signatories
5. List Designated staff for Planning Engineer Project -do- Designated
Inspection of Materials Manager staff list
7. Review of Bulk Material Planning Engineer Project By 15th of
Status Manager every month
8. Invoicing Planning Engineer Project By 5th of every
Manager month
9. Certification of Bills Planning Engineer Project Before last day
Manager of every month
10. Reply on Customer QA Project Within 3 days Customer
complaints with action plan Manager of receipt complaint
register
11. Action taken on customer QA SCI - -do-
complaint
Page 30 of 76
REVIEW OF BULK MATERIAL STATUS

(To be prepared by Planning Engineer weekly and approved by PM)
Date …
Sl. Items of Material Qty req. for the Qty in Lead time Qty to be Release
No. next two weeks stock for supply ordered P.O on
1 Aggregates
40 mm
2 20 mm
12 mm
3 Sand-Med. coarse
4 PS Cement
5 Reinforcement HYSD
6mm
8mm
10mm
12mm
16mm
20mm
25mm
32 mm
6 Soling Bricks
7 II Class Bricks
8 Jhama Bricks
9 Filling Sand
10 Any other material
Prepared by Reviewed By
Planning Engineer Project Manager
Page 31 of 76
13. Method statement for construction of Roadwork

Objective: To establish the construction procedure, equipment required, Contractor role and Specification
requirements of road construction for the following activities:
Survey
Setting Out:-Fixing of centerline & toe line fixing (road alignment/cross-section).
Roadway - clearing & grubbing
Excavation
Base preparation
Embankment filling
Sub-grade construction
GSB construction
WMM
Concreting General (For CD works, Bridge works.)
Backfilling, Compaction, Rubble Packing
Cement Concrete Flooring
Reinforcement Cutting, Bending, Fixing
Form-work
Structural Work covering survey & setting out, Excavation, Construction of Foundation, Construction of Column,
Beams & Slabs, Painting, Filling around foundation & Plinth, PCC.
Pitching
Turfing
Road Furniture
Page 32 of 76
Survey
Objective – To set out the structure in accordance with drawings from the reference points provided by the
Project Consultants. To provide permanent gridlines and construct benchmarks for level control. Carry out routine
survey work, identify errors, distribute errors and maintain survey records. To record cross section level for
finalizing the qty. & to get the required profile.
Equipment Required:- Theodolite, ranging rod, auto level, staff, EDM
Procedure:
Sl. Activity Responsibi Check by Remarks / Records File
no. lity Ref.
1. Obtain Client’s drawings, prepare site Surveyor Section
survey drawings. Locating the positions Engineer Site Drg. / Sketch
of grid stations, benchmarks, etc.
Locate stations such that they will not
2. be disturbed during construction. Site Surveyor
Engineer Size-
Construct Control Stations, BM Stations (150x150x1000)m
as per Sketch.
3. Section Surveyor
Mark grid intersection with steel nail Engineer
embedded in concrete block
4. Site Engineer
Paint grid references and fence Engineer
“Stations”
Designate value to benchmarks, close LIST OF TBM &
5. traverse. Surveyor Surveyor GRID POINTS TO BE
CIRCULATED
6. Surveyor Engineer
7. Obtain daily survey requirements of Surveyor Section The Surveyor will be

Section Engineers during Site Meeting. Engineer involved in initial set
Carry out routine requirements. out only. The
responsibility for
transfer of Lines and
Levels is with the
Section Engineer.
8 PAINTING TO BE DONE TO IDENTIFY SURVEYOR SKETCH
THE PROPOSED CENTER LINE & / SECTION
REFERENCE CENTER LINE ENGINEER
NON-CONFORMITY: -Non approval of Client.
Page 33 of 76
CORRECTIVE ACTIONS FOR NON-CONFORMITY:- As directed by Client
Setting out
Objective:- Fixing of working bench mark, traverse pillars, grid pillars, centre lines / setting of curves &spot
levels drawing in co-ordination with site in charge and getting it checked with clients. in co-ordination with site in
charge.
Equipment Required: Theodolite, ranging rod, auto level, staff, EDM
Sl.no Activity Responsibility Check by Remarks / Records File

Ref.
1. Establishing working Project Established Reference bench
BM w.r.t. GTS BM Surveyor team/once every mark and record of all bench
-Control points month marks in survey file
@ 200mtr & also at all Project team
CDW, Over Bridges,
Underpasses
2. Temporary Bench Surveyor Engineer at Reference to Working bench
mark- every months mark/ record in survey file
3. Setting out –Centerline Surveyor as per Engineer /as per Approved by Engineer on
& toe line MOST 109.3 MOST 902.2 stage passing format
Engineer
4. Profile survey at every Surveyor/ at w.r.t centerline & cross section
10-mtr interval. intervals as Engineer / records in survey file.
required by
Engineer
CORRECTIVE ACTIONS FOR NON-CONFORMITY:-As directed by Client
Role Of Contractor
The contractor have to maintain the center line pillar on both side and will be responsible for shifting it as
and when required to main carriage way during construction of embankment/subgrade. More over in every layer
of filling the contractor have to mark the toe line
Before field testing starts which would be checked by the section in charge to avoid any extra laying done & also
to check the maintenance of required toe.
Roadway - Clearing & Grubbing

Equipment Required-Dozer, Excavator, Dumpers
Procedure: After fixing of center line , toe line & on the completion of cross section levels the clearing &
grubbing activity is to be taken up .The formation width has to be made clear of any vegetation if present. The
Page 34 of 76
procedure adopted will be to completely doze about 150mm and make the stretch completely clear of material
like bushes, shrubs, stumps, grass, weeds, top organic soil etc. The dozed material have to be cleared from toe
width extent completely, wherever the roots stumps are located and are unresolved by dozer will have to be
excavated out and disposed off. All excavation below general ground level arising out of removal of trees, stump
required to be filled with suitable material and compacted thoroughly so as to make the surface at this point
conform to surrounding area. If area is water logged it has to be dewatered and made to expose to sun till it dry
out. In case of perennial watercourse sand filling will be resorted to at least 0.5 mtr above the pond water level
after obtaining approval for variation from the Engineer. Underground services, if any, will be brought to the
Engineer’s notice. For Undercutting & removal of unsuitable material, if any, measurements will be taken before
& after the activity to ascertain the qty, involved. After stretch is made clear, the base preparation activity follows.
Role of contractor: Whole activity as discussed above will be part of contractor scope.
Documentation: As Specified in Inspection & Test Plan (ITP)

Excavation
Objective – Excavate for construction of roadway to the required dimensions and levels as per drawing,
removing excavated earth, storing for reuse or disposal at places agreed with clients
Equipment:- Excavator, Tipper
Sl. Activities Remarks/ File

no Responsibi Check by Records Ref
lity
1. Set out Excavation limits at Ch. Hand Section Engineer Note in site order
every 50-meter interval in plain book with
terrain and at 20-meter sketches.
intervals in all curve points true
to lines, curves, slopes, grades
and sections.
2.
Agree with clients for disposal Section Construction Location of
area, inform client of quantity, Engineer Manager disposable area
Reusable material may be record to be
stacked 10-15m away from maintained.
3. excavation.
Check ground water levels and Ch. Hand Section Engineer

induct dewatering systems if
4. req. Keep standby DW
Systems.
Ch. Hand Section Engineer-
Excavate manually or Format-
mechanically to required sizes LTHCC/EXE/EXC/
5. and depth. Make sure depths Ch. Hand Surveyor 01
are not exceeded beyond
Page 35 of 76
requirement.
Note in Site
Trim and Level manually at final Instruction Book.
level (tolerance 20mm)
Documentation: As Specified in Inspection & Test Plan (ITP )

__________________________________________________________________________________________
Base Preparation
Objective: The base is to be prepared and to be graded and rolled properly over which embankment
construction will start.
Equipment required: Grader, Roller, and water tanker
Execution procedure.
Sl. Activity Responsibilit Check by Remarks/ Records File

No. y Ref
.
1 The base sample is taken and QC-dept Engineer QC density test
given to QC Dept to determine record
modified proctor density. Format:
2 After bed preparation, field QC-Dept Density of 95%
density tests should be carried out compaction on
for degree of compaction. MDD
Role of contractor: The above said activity is to be carried out by contractor and only testing part is in
L&T’S scope.
NON CONFORMITY: -
When the ground does not have 95% relative compaction with respect to the dry density.
CORRECTIVE ACTIONS FOR NON-CONFORMITY:-
The ground will be scarified, water will be sprinkled uniformly with a controllable rate and thoroughly
mixed in soil by blading, discing or harrowing to obtain uniform moisture content throughout the depth
of the layer. Then the soil will be compacted by vibratory roller. Control of moisture will be tested by
rapid moisture meter .
Documentation: As specified in ITP.
Page 36 of 76
Embankment fills
Objective:- Filling the embankment with approved borrow area materials, spreading, grading, watering &
compaction to designed Density .
EQUIPMENT REQUIRED- Excavators, dumpers, water tankers, roller, dozer, motor graders .
Procedure:
Sl Activity Responsibility Check by Remarks/ Records File
.n Ref
o
1 The approved borrow Site Engr. QC-Dept Material as per MOST
area material is 305.2.1.Records –
brought on the stretch. approved test reports for
the borrow area
2 The dumped material Site Engr Section Corrective action for

is to be dozed and Engineer layer thickness in excess
spread properly. Layer of required is to move
not exceeding 300mm material from excess
tk.. (compacted : zone to deficient zone
250mm th) Records – FDD Test
reports
3 The spread material contractor Site Engr
should be made free of
deleterious materials
like-twig, stem and
bigger size clod if
present.
4 The spread material is Grader operator Contractor/Site
to be graded to Engr.
required camber.
5 The stretch is to be Site engineer /as QA&C-Dept The amount of water to
watered properly so as per MOST305.3.5 OMC and MDD be added to the soil will
to achieve requisite for the light be calculated as OMC
OMC, if not already compaction- 2 minus NMC and 1%
available. test for every above to 2% below the
3000 m3 of soil. OMC will be added for
evaporation and other
measures
6 When moisture content Site in charge / as QC Engineer
of stretch has reached per MOST 305.3.6
requisite OMC, the
stretch is to be rolled
to achieve desired
Page 37 of 76
compaction.
7 After rolling the test will Implementation by QC- Dept / The results will be
be carried out to check Planning dept Compaction prepared in set of 3 copy
the required The program of -95% as per (one-contractor, one-QA,
compaction is testing including table-300-2 CL one- QC, one-planning
achieved or not stretches which 900 MOST dept) the result will have
will be getting a comment written by
ready during QC section in charge.
course of second
day will be given
by contractor to
QA/QC dept by
evening of day
before.
8 Rolling will be Site engineer In areas of cross fall

commenced at the (camber) on both sides,
lower edge and rolling will be
proceeded towards the commenced from the
upper edge edges and proceeded
longitudinally for the towards the center.
areas of unidirectional
cross fall (camber) and
super elevation.
9 Camber preparation Contractor Site Engineer This will be helpful for
string method is to be not only camber
used.. preparation but also for
visitors to judge at what
stage filling is in
progress
1 Formation layer nos. Contractor Site Engineer on culvert, abutment
0 shall be marked by where ever slab culverts
paint is located and in rest of
area it can be marked at
least 50 m c/c using
concrete post.
Non Conformity: -
Maximum dry density less than specified dry density
Standard deviation of at least 5 test results should be below 0.08g/cc
Corrective action
Increase nos. of passes, scarify, control the moisture and re-compact.
Page 38 of 76
In case SD is more than 0.08g/cc increase nos. of tests and identify stretch showing wide variation from
mean field dry density. Sort out problem by doing confirmatory tests for sample collected from
varying stretch area and confirm the fill material test record & location
Documentation:-As specified in ITP.
Subgrade preparation
Objective :- To prepare the Sub grade with approved borrow area materials, spreading, grading,
watering & compaction to designed density .
Equipment Required : Grader, Roller and Water Tanker, Excavator, tipper, Dozers
Procedure:
Sl. Activity Responsi Check by Remarks/ File
no bility Records Ref.
1. Material:-
a. When the sub-grade to be prepared, QC-Dept QC-dept QC record
the soil will be checked for a One CBR test /
minimum CBR value of 10% in the 250m length of
laboratory on the remolded samples road.
in soaked condition.
b. The sub-grade material will be Site Corrective action FDD Test
spread in layers of uniform thickness engineer To move material report
and compacted and finished by from excess
motor grader. Layer thickness not to zone to deficient
exceed 200mm. zone
2. Water application:-
a. Optimum moisture content (OMC) QC-Dept Engineer Test reports
and maximum dry density (MDD)
will be found out for the light
compaction at the frequency of 2
tests for every 3000 m3 of soil.
b. The amount of water to be added to
the soil will be calculated, as OMC
minus NMC and 1% above to 2%
below the OMC will be added for
evaporation and other measures
c. The amount of water required for
bringing natural moisture content to
optimum moisture content will be
sprinkled from a water tanker
uniformly with control rate of flow
3.Mixing of soil :-
Page 39 of 76
a. After adding the required amount of Site

water as per 5.3.6.3, the soil will be engineer
mixed by means of graders,
harrows, rotary mixers (rotators)
until the layer is uniformly wet.
Clods and hard lumps of earth will
be broken to a maximum size of
75mm.
4.Compaction:-
a. Each layer of the material will be Site layer thickness
engineer < 200
thoroughly compacted to the
specified densities by a vibratory
roller having a static weight of 8-
10 tons.
b. Rolling will be commenced at the Site In areas of cross
lower edge and proceeded engineer fall (camber) on
towards the upper edge both sides, rolling
longitudinally for the areas of will be
unidirectional cross fall (camber) commenced from
and super elevation. the edges and
proceeded
towards the
center.
c. Field density tests will be Site QCE /3rd Format
conducted by sand replacement engineer party
method at a frequency of one (Project
measurement for every 250 consultant)
m2 of compacted area for each
layer.
d. After completion of cut and fill Site
operations, the surface will be engineer
proof rolled by 4 passes of a 10-
ton roller.
e. Formation layer nos. shall be Contract Site Engr On culvert,
marked by paint or abutment
whereever slab
culverts are
located and in rest
of area it can be
marked at least
50m c/c using
Steel rod.
Non Conformity: - Corrective action
Mean dry density of 10 test results should not Increase nos of passes, scarify, and control the
Page 40 of 76
be less than specified dry density moisture and re-compact.

Standard deviation of at least 10 test results In case SD is more than 0.08g/cc increase nos
should be below 0.08g/cc of tests and identify stretch showing wide
variation from mean field dry density. Sort out
problem by doing confirmatory tests for sample
collected from varying stretch area and confirm
the fill material test record & location.
Page 41 of 76
Granular Sub Base

Objective:-Laying and compacting well-graded material on prepared subgrade in accordance with the
requirement of MOST 401.1.
EQUIPMENT REQUIRED: Excavator, dumpers, wheel loader, grader, water tanker, and vibromax.
Procedure:
Sl. Activity Responsibility Check by Remarks/ Records
no.
1 The sand mixed with gravel will Stores to certify
be brought to borrow area qty of sand with
identified through stores gravel
2 This material brought to site will Site engineer QA/QC QC DEPT- give the
be stacked properly as shown in DEPT. / as ‘GO AHEAD”
the sketch . The binder earth will per MOST
be excavated and stacked in 401.4.2
same borrow area and mixed.
3 GSB Mixing will be done at stack QCE Engineer
yard as per designed proportion
(volume wise). The material after
dumping at Site is to be sent to
QC for gradation checking. Upon
approval from Engineer, the
material dumped will be laid
through Motor Grader.
4 The sub base layer will be laid in Site engineer
single layer of thickness 200mm
by motor grader
5 After adding the required amount Site engineer
of water (i.e. 1% above to 2%
below the OMC requirement ), the
material will be processed by
mechanical means like disc
harrows, rotavators until the layer
is uniformly wet.
6 Each layer will be compacted by a Site engineer Surface
Vibratory roller of 8 to 10 Ton Tolerance:-
capacity. -20mm,
+10mm
FDD: 98% Of
MDD(IIIrd
party Project
consultant )
7 Rolling will be commenced at the Site engineer In areas of cross fall
lower edge and proceeded (camber) on both
Page 42 of 76
towards the upper edge sides, rolling will be

longitudinally for the areas of commenced from the
unidirectional cross fall (camber) edges and proceeded
and super elevation. towards the center.
8 Rolling will be done uniformly SE QA/QC The speed of the roller
overlapping the preceding pass of will not be exceeded by
rolling by not less than 1/3rd of the 5km per hour.
track.
9 The grade and camber will be SE Surface Any high spots or
checked during rolling work for Tolerance:- depressions will be
high spots or depression. -20mm, corrected by removing
+10mm or adding fresh
FDD: 98% Of material.
MDD(IIIrd
party Project
consultant )
10 Rolling will be continued till the SE QC
field density is achieved
Mean dry density of 10 test results should not be Increase nos. of passes, scarify, and control the
less than specified dry density. moisture and re-compact.
Standard deviation of at least 10 test results should In case SD is more than 0.08g/cc increase nos of
be below 0.08g/cc tests and identify stretch showing wide variation
from mean field dry density. Sort out problem by
doing confirmatory tests for sample collected from
varying stretch area and confirm the fill material test
record & location.
Wet Mix Macadam (WMM)

Objectives:- Laying and compacting clean, crushed , graded aggregate and granular material,
premixed with water, to a dense mass on a prepared sub base ( GSB) as per the requirement of MOST
406.0.
The material shall be laid in one or more layers as necessary to lines, grades and cross section shown
on the approved drawings.
Equipment required: Wet Mix Plant (160t/Hr), Grader, Roller, Water Tanker, 62.5 Kva Dg Set, Wheel
Loader
Before the start of this activity following sub activities has to be carried out.
1) Identifying the location of plant preferably equidistant from both start & end of the package.
2) Construction of foundations
3) Erection of plant
4) Identifying the aggregate source and confirm the acceptability as per MOST table400-10/11
Page 43 of 76
5) Transportation of aggregate & stacking near the plant

6) Preparation of job mix formula
PROCEDURE :-
Sl.no. Activity Responsibility Check By Remarks/
Records
Wet Mix Macadam will be Plant engineer QCE/Engineer The granular material
1 prepared, as per the designed will be of crushed
proportion, in the Pug mill plant stone conforming to
with controlled addition of water. the: MOST 406.2.1.1
The wet mix will be spread either Site engineer Surface Tolerance- The required camber
2 by a paver finisher or motor +10mm,-10mm/ will be given using
grader to the full width of peg and string
formation (i.e. carriageway & method. /
hard shoulders) without the Surveillance
segregation of larger and finer observation checklist
particles.
3 Immediately after mixing, the Site engineer

aggregates will be spread
uniformly and evenly upon the
prepared sub grade/sub base in
layers of 180 mm uncompacted
thickness. Where more than one
layer is required, then each layer
will be of approximately same
thickness.
4 Each layers along forms, kerbs, SE
walls or other places which are
not accessible to the roller, will
be thoroughly compacted (to
achieve 98% relative
compaction) with mechanical
tampers or a plate compactor.
5 Skin patching of a surface area SE
will be scarified to permit the
proper bonding of added
material.
6 After the rolling is completed the SE QC-dept-98% The rolling is to be
stretch is to be tested for degree MDD(heavy done by 8 passes of
of compaction. compaction) as per roller. FDD Test
IS 2720 report
( Part – 8 )/IIIrd
party (Project
consultant).
7 After final compaction of WMM SE
Page 44 of 76
course, the road will be allowed

to dry for 24 hours. No vehicular
traffic of any kind will be allowed
on the finished WMM surface till
it has dried and the wearing
course laid.
8 Maintain all relevant records in Site Engineer CM/QA-team Audit reports
standard formats as per
Performa.
Preventive actions to be taken

Before laying and spreading of material, the shoulder on both sides will be constructed in advance. This
will laterally confine the wet mix macadam while compacting.
No depression should be filled with unmixed and ungraded, material
or fines.
Mean dry density of 10 test results Increase nos of passes, scarify, control the moisture and re-
should not be less than compact.
specified dry density.
Standard deviation of atleast 10 test In case SD is more than 0.08g/cc increase nos of tests and identify
results should be below stretch showing wide variation from mean field dry density. Sort out
0.08g/cc problem by doing confirmatory tests for sample collected from
varying stretch area and confirm the fill material test record &
location.
3. Surface irregularities Irregularities should be within recommended tolerances if not , then
loosen, add or remove , level and recompact. Minimum patch area
should be 5m longX2m wide
Concreting General
OBJECTIVE – To ensure, right quality of mix is manufactured, placed and vibrated such that the structure achieves the
desired finish, strength and thereby durability. The procedure ensures quality of Shutter & concrete, Equipment’s used and
provision for stand-by Equipment / Crew.
Equipment Required:-Batching Plant OR 10/7 Mixer Machine, Way batcher, Transit Mixer/Tetra
Procedure:
Sl. Activity Responsibility Check Remarks / Records
no
1. Prepare Concreting Planning Construction Copy to QCE/P&M
Page 45 of 76
Program for the following Engineer/Engine Manager

week every Saturday. er in charge for
Obtain inputs from all structure
Section Engineers.
Ensure availability of
Aggregates, Sand, Stores Planning Physical check and
2. Cement Admixtures, etc., Engineer confirmation.
to meet the program.
If Raw Materials are
deficient, initiate action.
Ensure Batching Plant,
Transit Mix, Pump are Stores Planning
3. maintained on the holiday Engineer
& after the running task is
completed as per P&M Construction
4. schedule. If problems are Engineer Manager
anticipated, provide for
standby or alternate
supply.
For bigger Pours, standby
is mandatory. Obtain advance
permission from
Consultants. Keep
Contemplate emergency CM ready Stop ends and
stop-end procedures in P&M Carpenters. Instruct
5. addition to Step 5. Engineer procedure to site crew
before leaving site. This
Site to be written as a
6. Engineer standard procedure.
Page 46 of 76
7. Check Pour Card has Engr in charge - Set priority for Pour.
been approved. (structure ) Inform Site Engineer
Reinforcement
8. Reinforcement work, If Engr. Site Engr./
any, to be prepared for Engineer
the job
Site Engineer
Shuttering/ supports work Engineer
9. should be completed &
checked
Notify Batching Plant -

through note for delivery Engr in charge
of concrete. (structure ) Conc. Request note
10.
Site Engineer to set up -
Crane or Pump in
position, check all QCE will not batch
11 equipment’s (Vibrator, Section without site clearance.
Compressor, etc.). Keep Engineer
Stand-bye available.
Confirm mix instruction to
QCE by Wireless /
Intercom or any other
mode.
NON-CONFORMITY: -Concrete Grade is not correct, Reinforcement not as per drawing, Shuttering not as per
requirement, pour card not filled up properly.
CORRECTIVE ACTIONS FOR NON-CONFORMITY:-Check the Concrete Grade is as per drawing

,Reinforcement /Shuttering to be approved by Client, Pour card should be duly filled
Backfilling, Compaction, Rubble & Filter Material Packing
OBJECTIVE – Backfill and Compact areas around structures in layers not exceeding 200mm loose,
trim to correct levels, rubble pack to level, place vapour barrier.
Equipment Required:-Mixer M/c,
Procedure:
Sl. Activity Responsibilit Check Remarks
No y By
.
1. Bench the vertical sides of Ch. Hand Section
Page 47 of 76
excavation such that Engineer

adequate space is created
between the SS Masonry and
Excavation to allow a Place
Compactor inside.
Mark Layer Levels and Visual check by QA

Number (on Masonry). Engr
2. Sample Backfill material, Ch. Hand

determine OMC and MDD.
QA
Premix water in the fill
3. material, maintain +2% above QCE
optimum, spread to required
level, compact using Site
Compactor (Min. 10-12 Engineer
4. passes). Ch. Hand
Determine Insitu Density

(Min. 3 tests per 200m2).
Proceed with compacting in Site

layers till reqd. level is Engineer
reached.
Site
5. Complete all services, QCE Engineer
backfill.
Site
6. Ch. Hand Engineer
Services
7. Engineer
* Imp. * Imp.
8. Provide Vapour Barrier of Ch. Hand Site The detail to put Vapour
LDPE immediately after Engineer Barrier over Rubble is not
compaction. acceptable as this may have
detrimental effect on flooring.
Consult with Designer and
change detail.
Manually place 100-150mm Ch. Hand Site If profitable, propose 1:4:8

9. Rubble Stones, fill interstices, Engineer cone in lieu of Rubble
spread Sand or Crusher packing if it is cheaper.
Page 48 of 76
Dust, Water and Roll with 8-

10 Tonee Static Roller if
required.
Check level, control Ch. Hand Site

undulations. Engineer
Manually place the Filter Ch. Hand Site

10 Material as per gradation Engineer
behind the wall wherever it is
specified in Drg.
11.
Page 49 of 76
Reinforcement Cutting, Bending, Fixing
OBJECTIVE – Receive, Stack diameter wise, approved quality of reinforcement, cut, and bend as per
prepared bar schedules. Ensure minimum wastage and generation of scrap.
Equipment Required:- Reinforcement rod cutting Machine
Procedure:-
Sl. Activity Responsibilit Check By Remarks
No y
.
1. Obtain Construction drgs., Section Planning / Do not consider any

prepare barlist, placement Engineer QA wastage here.
drgs. and sketches. Work
out quantities.
Consolidate diameter wise
requirement including
2. delivery schedules. If Planning Construction
barlists are prepared by Engineer Manager
Consultant check by Site
Engineers.
Quality reinforcement
Suppliers by independent
tests or reviewing Test
Certificates.
QA
3. Place Order. QCE
Receive Consignment,
stock diameterwise on
Sleepers min. 300 above
ground. Tarpaulin cover the CM
4. lot. Stack to be in line with Planning
Cutting Machine. Engineer
Construction
5. If Steel is not tested before Reinforcement Manager
delivery, collect samples Engineer /
and send for test Stores
Page 50 of 76
QA
Reinforcement
6. Engineer
/QCE
7. Receive bar schedule and Reinforcement Section Section Engineer to
site priority from Planning Engineer Engineer follow up his request
Engineer. with planning.
Cut, Bend, bundle tag Reinforcement PREPARE BBS

8. reinforcement check with Engineer Section
Section Engineer and Engineer
dispatch to site.
Receive reinforcement site, Ch. Hand
count numbers, tally with
9. tag and BBS.
Mark spacing using chalk,
place bars for both
directions and fix. Place Ch. Hand
cover. Beams are generally
10. fixed in advance of slabs,
columns can be
prefabricated, etc.
Check for Cover, Spacers.

Use format CGWP.
Ch. Hand
11. Section
Engineer
Form Work
OBJECTIVE - To construct Form-work for Retaining Walls, Columns, Beams, Slabs, etc. true to
dimensional requirements, water tightness, rigidity, etc. as per Designs / Standard practices.
Page 51 of 76
Procedure:-
Sl. Activity Responsibilit Check By Remarks

No y
.
1. Review Construction drgs.,
design system form work, Planning QA .
prepare form work drawings / Engineer
sketches.
2. Calculate material Planning

requirement based on drgs., Form Work Engineer
consider possible repetitions Engineer RPM
& others.
3. Indent materials to Regional Planning CM

Formwork Co-ordinator. Engineer
Indent Plywood, etc. through Planning

4. Regional Purchase. Engineer Site Ensure cutting waste.
Engineer
Fabricate standard Panels for Carp. Ch.
Ret. walls, Columns, Beam Hand
5. sides as per drawings.
For insitu forms – place props Carp. Ch.

over solid bases PCC or Hand
Timber over compacted Use Survey Format.
6. ground, Brace props, place U
heads, Timber beams, etc. as
per spacing, levels. Surveyor
Level system; check all cross- Carp. Ch.

falls, joints, etc. are as per Hand
day.
7. Clean, apply mould release,

place Reinforcement,
Concrete.
De-shutter at specified time

and strength without shock,
stack all components neatly
for reuse.
Page 52 of 76
Pitching
OBJECTIVE – To control the soil erosion of the embankment slopes
Equipment required: - Excavator, Dumper.

No y by
.
1 The surface to be pitched shall Site Engineer Section

have been previously constructed In
& trimmed to the required slope Charge
and cross section as per Drg..
Depression if at all present shall be Site Engineer

2 filled by soil and thoroughly Section
compacted. In
Ch. hand Charge
Filter granular material shall be laid
and compacted thoroughly up to Site
3 specified thickness. Engineer
Pitching shall be started from the

toe wall and a toe protection is Ch. hand
necessary. Engineer
4
Page 53 of 76
Turfing
OBJECTIVE – To control the soil erosion of the embankment slopes
Equipment required: - Excavator, Dumper..
Procedure: -

No y by
.
1 The surface to be turfed shall have Site Engineer Section

been previously constructed to the In
required slope and cross section. Charge
Where required, topsoil be spread Site Engineer

over the slope. Section
2 In
Each sod strip shall be laid edge to Ch. hand Charge
edge and such that the joints
3 caused by the abutting ends are Site
staggered. Engineer
After the sods have been laid in

position, the surface shall be Ch. hand
cleaned, Engineer
4 And watered for a period of at least
4 weeks after laying.
14. Purchasing
Page 54 of 76
Objective: To Streamline site& Regional office purchases and define boundaries for
Materials, Services (Specialised s/c) for the execution of the project.
Scope: All the materials and services for the site.
Purchasing Information, Verification of purchased product
Sl.No Procedure description Responsibi Reference Record / Record

lity document Document distribution
/ data
1 Prepare List of Materials Planning Drgs. / S6 PM
against time required Engineer Specs.
3 Agree details with all Planning - - -

depth in the kick off Engineer
meeting
4 Raise PR for materials Planning Drgs. / PR
Engineer Specs.
5 Prepare the list of Planning & Contract Circular Planning ,
approved material QAQC Document Stores ,
source ,& manufacturer QAQC,A/C
5 Give the list of Approved Planning Contract QA,QC,
material source / vendor Engineer/ spec or stores ,
as applicable per contract, Purchase approved planning
or purchase the materials department vendor list
as per our approved of
vendor list. Purchase
6 Forward to Purchase PM as PR List
section after approval. applicable
7 Procure material Purchase - -
department
8 After receipt of material at Stores DC MRIN PLANNING
site stores, the same has incharge / QC
to be informed to qaqc &
planning
9 ISSUE ONLY Stores
APPROVED MATERIALS incharge
TO SITE
Page 55 of 76
Flow Chart of Procurement Procedure for
Construction Material of Natural Origin
SELECTION OF SOURCE
PM/CM
SAMPLE AND TEST

Q.C. ENGR.
APPROVE SOURCE NOT APPROVED SOURCE

CLIENT / Q.C.ENGR.
PLACE ORDER AND RECEIVE

STORES INCHARGE
USE MATERIAL FROM SOURCE
ROUTINE TESTS
Q.C.ENGR.
DISCONTINUE USE
NOT MEETING
ROUTINE TESTS MEETS SPECIFICATIONS
SPECIFICATIONS
REWORK / RETEST
CONTINUOUS USE
CONTINUE IF MATERIAL
MEETS SPECIFICATIONS
NOTE: ALL STEPS IN THE FLOW CHART REQUIRE

DOCUMENTATION AND RECORDS
Flow Chart of Procurement Procedure for

Manufactured Items
Page 56 of 76
RECEIVE MATERIAL REQUIREMENT FROM SITE

(RECORD IN MATERIAL REQUIREMENT
REGISTER)
VERIFY PROVISIONS AND FORWARD MR TO

PURCHASE DEPARTMENT
(PLANNING)
FOLLOW REGIONAL PURCAHSE PROCEDURE
RECEIVE MATERIALS AT SITE STORES

STORES INCHARGE
SEND MATERIAL RECEIPT

VERIFY MATERIAL FOR CONFORMANCE INFORMATION TO PLANNING
DESIGNATED STAFF / QA ENGR. & MRN TO KKRO
ISSUE ONLY ACCEPTED REJECT MATERIALS NOT

MATERIALS FOR SITE USE MEETING SPEC
STORES INCHARGE DESIGNATED STAFF /
Q.A.ENGINEER
FOLLOWUP WITH VENDOR FOR

REPLACEMENT / REWORK
STORES INCHARGE
ALL STEPS IN THE FLOW CHART REQUIRE DOCUMENTATION AND RECORDS
Page 57 of 76
MATERIAL RECIEPT INFORMATION NOTE

(TO BE MAINTAINED BY STORES)
PROJECT :
DATE :
SR MATERIAL QUANTITY MRNo. BATCH UNLOADED REMARKS

No. No. AT
P.S : THIS FORMAT HAS TO BE FILLED EVERY DAY FOR EACH ITEM WHICH IS GOING IN TO
PERMANENT WORKS AND SEND TO QAQC & PLANNING DEPARTMENTS
Page 58 of 76
15. Preservation Of Product

[Handling, Packing, Storage And Delivery]
Objective: To establish a procedure for Handling, packing, storage and delivery of materials
both our and also client supplied.
Scope: All materials / products
HANDLING

No document / distribution
data
1 Maintain a list of materials Site Relevant List of
Perishable Accountant code of material
Non perishable practice / and
contractual records of
document storage
2 Follow first in and first out for Site Relevant Issue
perishable items or those Accountant code of register
having shelf life, stock practice /
batchwise with identification contractual
(cement , admixtures Etc) document
3 Follow applicable test for QA Engineer Inspection
perishable items if in long and testing
storage procedure
4 Follow housekeeping Section Heads House House
instructions, for preservation keeping keeping
of end product. Inspection Inspection
Sheet Sheet
STORAGE

data
1. Identify Items that require Site Manufactures
special storage Accountant recommendat
Ex.:Manufacture ions
recommendation etc. for
admixtures , detonators
2. Provide the facility as Site
required Accountant
3. Follow storage inspection Site
Accountant
Page 59 of 76
PRESERVATION

data
1. After the product is CM/Site in- As per
manufactured, in this case charge contract
Buildings or fabricated and
erected structures, the same
is kept in clean condition and
handed over to clients.
2. When stage wise handing CM/Site in- As per
over is there necessary charge contract
formats are filled for handing
over.
3. After final handing over CM/Site in- As per
necessary completion charge contract
certificate is obtained from
client.
Page 60 of 76
16. Control of Monitoring And Measuring Devices
Objective: To establish and maintain a procedure to calibrate and to maintain the inspection and test
equipment to ensure that the equipment are capable of performing to required accuracy.
Scope: To streamline Calibration Procedure for all Measuring and Test Equipment’s as specified in the
list below.

data
1 Prepare list of measuring QC Engineer Master List
equipment of
Equipment
Calibration
2 Prepare sequence of QC Engineer Equipment
calibration and location calibration
table
3 Calibrate testing equipment QC Engineer Relevant
and maintain record. calibration
records
4 Protect from damage and ALL Users
deterioration during handling,
Maintenance and storage.
5 Assessing and documenting QC Engineer
the validity of previous
inspection & test results
when Non conformity is
found.
6 ENSURE THAT THE QC Engineer CALIBRATI
MASTER EQUIPMENTS ON
ARE CALIBRATED BY AN CERTIFICA
APPROVED AGENCY TE
(Note: Master Equipment’s means Those Equipments which will be used to calibrate other
equipments in-house. like Tape , Steel Scale , Thermometer , Stopwatch , Measuring Cylinder
Etc. )
Page 61 of 76
17. Internal Quality Audits

Objective: To monitor and check continuing suitability and effectiveness of the Quality Management
system
Scope: Documented Quality Management System
Sl Record
N Procedure step Responsibil Document Record distributio
o ity n
1 Prepare Audit plan for the project QA - site Audit Audit Plan / Section
Calendar Calendar Heads
2 Give audit notification to the QA Engineer Audit Section

concerned department & get the Notification Heads
Acknowledgement
3 Prepare checklist points based on Auditor
section procedures
4 Perform Audit on Scheduled time Auditor, SH
5 Review pending NCR’s and close Auditor NCR’s Section
if satisfied, raise fresh NCR, in R GEN 14 F Heads
case of identification of objective 03
evidence of non conformity
6 Seek acceptance of NCR by Audi Auditor
tee, Issue NCR
7 Follow-up with concerned QA Engineer Closed Section
departments for closure of NCR’s NCR’s Heads
8 Summarise NCR’s, Status, QA Engineer Audit
Present for management review summary
meeting at site level to initiate
preventive action
9 Update Audit Plan cum record QA Engineer Up dated
(refer step 2) audit Plan
1 Reschedule leftover audit (if any) QA Engineer Subsequent
0 to subsequent quarter Quarter
Audit
Schedule
Page 62 of 76
REGION: SITE: MONTH:
DATE OF AUDIT :
PREVIOUS AUDIT REPORT:
AUDIT TEAM :
PERSONS CONTACTED :
AUDIT SCOPE AND OBJECTIVE :

(DESCRIBE THE AREA AUDITED)
† AUDIT SUMMARY:
Total NCR’s ISSUED CATEGORY:

1 2 3 4 5 6
No of NCRS :
OBSERVATIONS ISSUED
Return original by Regional QA, Copy to HQ – QA and site.

* Use separate sheet of same format for each site.
Describe site co-operation, issues and proposed action by site. Highlight serious NCR’s / Repeat NCR’s.
NON-CONFORMING SITUATION:
Category 1 - Incorrect completion of Forms / Lack of Attention - Minor
Category 2 - That can be corrected by Auditee but requires approval of his Supervisor - Minor
Category 3 - Requires minor change of procedure with approval of Site Quality Mgmt. - Minor
Category 4 - Change a procedure that requires approval of Site Manager - Minor
Category 5 - Which is beyond site control and can be resolved by PM - Major
Category 6 - That calls for rejection - Major
Page 63 of 76
Audit summary
Audit No of balance No of NCR’s not closed in Time frame committed by Remarks

No NCR’s category 5 & 6 Auditee
Description of NCR not closed in category 5 & 6
Action Proposed by Auditee foreclosing the NCR with time frame
Auditor’s Remarks
AUDITOR: Management Representative ( Region):
Signature: Signature:
Page 64 of 76
Location: Date: Sl No: -
To: Section:
cc:
This notification is to advise that an Audit is scheduled to take place in your Site/Dept as
detailed below.
Please acknowledge receipt of this notification by signing and returning a copy of this form to
the MR ( R ).
AUDIT DETAILS:
Audit Number:
Scope proposed Accepted by Auditee
Date Planned:
Time:
Proposed Audit Scope:
The Auditor / Audit Team will be:
The following personnel will be required to be available during the audit:
Approved by
Received by
MR ( R ) / SH – QA ( R ) :
(Title):
Signed:
Signed:
Date:
Date:
Page 65 of 76
Monitoring and measurement of processes,
Sl Record
No Procedure step Responsibili Document Record distributi
ty on
SITE WORK
PROCEDURES,QAP AND
WORK INSTRUCTIONS
PREPARATION AND ISSUE
1 Prepare Quality Assurance Plan Site QA Contract Draft ITP
for materials which details Engineer / document,
stages of monitoring, measuring Site Engg IS codes
sampling, acceptance criteria, /CM
reference documents, records to
maintain and personnel
responsible to release the
product.
2 Prepare Work procedures and Site QA Contract Draft ,WP,WI
Work instructions in line with the Engineer / document,
following. Site Engg IS codes
Contract document /CM
Code of practice
ECC work procedure with all
details as given above.
3 Seek Review /approval from Site QA Notes
Project QA Head. Engineer
4 Where ever required Seek Site QA Engg
Concurrence from Client
5 Follow procedure 7.1 Planning of
product realisation.
6 Follow procedure 7.2 customer
related process
Page 66 of 76
CONTROL OF NONCONFORMING PRODUCT
Objective: To describe the responsibilities and methods used by the Management for control of Non-
conforming product /s system/service process and to ensure that the defective processes and products
are prevented for unintended use.
Scope: 1. Customer / consultant’s complaint letter

2. Audit Reports
3. Non-conformance Reports
REVIEW AND DISPOSING OF NON-CONFORMING PRODUCT

data
1 Identify Non-conformity in All Section List of non
product and document the Heads conforming
same products
2 Refer to QA and prepare All Section
action plan to review rework Heads
or reject and maintain
records
3 Classify the Non-conformity QA
4 Take actions as per guide All Section Contractual CA Report
lines / recommended by QA Heads document /
relevant code
5. Identify Non-conformity in Product /
Activity / Product process. Process
NCR
6. Refer to consultant, Site in charge Work Notes
PMC/client for review, rewrite procedures
or reset the Procedures and
maintain records.
7. Take actions as per Site In charge
corrective action given by
PMC/client.
Table ST 1
Page 67 of 76
SL. No Functional Scope Techniques used Responsibility Record Record
Area distribution
1 Work To monitor Gantt Chart / Planning Monthly PM / HQ
progress projected Vs Linear chart Engineer Progress
status actual report
Frequency -
Monthly
2 Cube test To establish Standard QC Engineer Monthly SCI
results degree of deviation report
Frequency- control
monthly
3 Invoicing Projected Vs ‘S’ Curve Planning Monthly SCI
Actual Engineer Report
4 Field density Consistency SD checks UCL QC Engineer Reports Consultant
test road to LCL as per
projects MOST
IMPROVEMENT
8.5.1 CONTINUAL IMPROVEMENT:

The management is committed to the continual improvement for the effectiveness of QMS by
effectively implementing in all the projects of B&IP ,with a documented Quality policy, set
targets , effective usage of audit results ,appropriate usage of analysis of data,proper
directions to take corrective and preventive actions and periodic and systematic Management
review.
CORRECTIVE AND PREVENTIVE ACTION
Objective : To describe the responsibilities and method used by management for corrective and
preventive actions
Scope : 1. Non conformance of Products / Process

2. Customer / Consultant ‘s complaint letter
3. Audit reports
CORRECTIVE ACTION
Step Procedure description Responsi Reference Record Record

No bility document / distribution
Page 68 of 76
data
1 Detect non-conformity through QA Control of non Non Auditor /
routine checks or audits- Raise Engineer conforming conforma Auditee
Non-conformity report as per products / nce
procedure for internal audit Internal Audits Report
2 Evaluate the NCR- Allocate the Auditee
Level of authority required to effect
remedial measures
3 Respond to the NCR with proposed Auditee Notes & SCI/
remedial measures and the date by proposals Auditor
which this will be completed as in NCR
agreed time by Auditee. formats
4 Implement remedial or corrective SHs
actions. Ensure the desired goals
are met.
5 Verify satisfactory implementation Auditee Closed SCI/
through re audit. Close NCR. NCR Auditor
PREVENTIVE ACTION
Step Procedure description Responsi Reference Record Record

No bility document / distribution
data
1. Discuss the following in SIC/QA Procedure for MOM SHs
Management Review meeting and Engineer Management
plan preventive action review
Repetitive NCR’s, Aged NCR’s
Root causes examined
Procedures examined / reviewed
New procedures deployed
Results observed etc.
2 Evaluate every NCR and Determine Auditee Preventive
the remedial actions initiated above action report
will prevent further non-conformities
of similar nature. If document
changes are required- initiate
process for the same
3. Discuss the product / input on NCR. CM / QA/ NCR's MOM(mo Engineer in
& Examine root causes. Procedure SECTIO nthly charge
is to be reviewed and reformulated N review)
for prevention of repetitive NCR. HEADS
Page 69 of 76
4 Critical process in work instructions Section Work MOM(mo All section
is identified and modified to prevent in charge instruction nthly incharges
occurrence of non-conformity. review )
Prepare process checklist.
5. Identify specific responsible person Section MOM All section

to monitor the preventive actions as In charge in charges
decided in monthly review & report
back in the next monthly review.
6. Review the improvement in the next SIC MOM All section

monthly review & repeat the action in charges
between (1) to (3)
Page 70 of 76
PREVENTIVE ACTION REPORT

NO :
DATE :
PROJECT : _________________________________________________________
PARTICIPANTS: _____________________________________________________
B. REPORTS ANALYSED
YES NO For the Remarks

Period
1. Customer Complaint Record
2. Non Conformity Reports
3. Major Rejections / Reworks
4. Inspection Concession / Waivers
Potential Cause identified, if any :
Auditee PM / SIC
Proposed Preventive action:
Auditee PM / SIC
Remarks after implementation of Preventive Action:
Auditee PM/ SIC
Page 71 of 76
PROJECT : DEPT :
SL NO File reference Contents of file Place of safe keeping

Holder Location Keep for (Years)
MAINTAINED BY :
SIGNATURE :
REVISION NO :
DATE :
Page 72 of 76
18. RECORD CONTROL
Sl
No DESCRIPTION DEPARTMENT
1 Permanent Bench Mark Pillars Check for SURVEY

Survey
2 Survey Details for pile points SURVEY

3 Cross section SURVEY
4 Level Check Sheet EXEC
5 Level Check Record SURVEY
6 Center Line Checking SURVEY
7 Daily surveyor Report SURVEY
8 Request For Inspection ALL
9 Borrow Area Location Plan QC
10 Sample Collection slip QC
11 Density of Free Running sand QC
12 Sand Equivalent Test QC
13 Sieve Analysis Of Sand QC
14 Specific Gravity Of Fine Aggregates QC
15 Inspection & testing for CA – Sieve Analysis QC
16 Flakiness Index of Coarse Aggregates QC
17 Specific Gravity Of Coarse Aggregates QC
18 Impact & Crushing Strength of CA QC
19 Los Angeles Abrasion Value QC
20 Brick Test Report QC
21 Sieve Analysis Of Soil QC
22 Moisture Content QC
23 Atterberg’s Limits QC
24 Density Test (Modified Procter) QC
25 QC
Page 73 of 76
Sample CBR
26 QC
CBR Test
27 QC
Free Swelling Index
28 QC
%CBR-% Compaction Graph
29 QC
Existing Soil Summary
30 QC
Borrow Area Summary
31 QC
Field Dry Density (sand Replacement Method)
32 QC
Aggregate 10% Fineness
33 QC
Aggregate Gradation Test
34 QC
Cement Test
35 EXEC
CONCRETE POUR CARD
36 QC
Concrete Cube Register
37 RE-BAR
Rolling Margin Of Reinforcement/ Structurals
38 RE-BAR
Abstract of Rolling Margin
39 RE-BAR
Bar Bending Schedule
40 EXEC
Quality Format – Check For Excavation
41 EXEC
Earth-Work Progress Report
42 EXEC
Piling Pour Card
43 EXEC
Record Of Piling
44 EXEC
Pile Bore Log Details
45 EXEC
Pile Reinforcement details
46 EXEC
PQC Paving Register
47 EXEC
Quality Format – Check For PCC
48 EXEC
Quality Format – Check For Back filling &
49 Plinth filling EXEC
Check For Anti-termite
50 EXEC
Check For DPC
51 EXEC
Quality Format – Check For Masonry
52 EXEC
Quality Format – Check For Door, Window &
53 Ventilator EXEC
Quality Format – Check For Plastering
54 EXEC
Page 74 of 76
Quality Format – Check For Flooring
55 EXEC
Quality Format – Check For Painting
56 EXEC
Check For Sanitary/Plumbing
57 QC
Softening Point Test Of Bitumen
58 QC
Penetration Test Of Bitumen
59 QC
Striping Value Of Aggregates
60 QC
Marshal Testing Data
61 QC
Temperature Details Sheet
62 QC
Blending Of Materials
63 QC
IS Codes list
64 PLAN/ EXE
Construction Drawing status
65 QA
RECORD CONTROL
66 QA
NON CONFORMITY REPORT
67 QC
CALIBRATION DETAILS OF TESTING
68 EQUIPMENTS QC
CALIBRATION OF BATCHING PLANT/ HOT
69 MIX PLANT SURVEY
SURVEY INSTRUMENT CALIBRATION
70 QC
INSPECTION & TEST PLAN (ITP) OF WORK
71 QA
SITE INSPECTION REPORT
72 QA
FREQUENCY OF TEST
73 QA
TRAINING RECORD
74 STORE
Monthly List Of Materials
75 STORE
Material Receipt Note
76 PLANNING
Monthly progress Report
77 PLANNING
Review of Bulk Material Status
78 STORE
Material Information Note
79 PLANNING
Work Measurement Record
80 PLANNING
Day Work Record
81 QC
Daily Meteorological Record
82 P&M
EQUIPMENT REPAIR RECORD
83 P&M
Page 75 of 76
JOB CARD
84 QA
AUDIT NOTIFICATION
85 QA
NON CONFORMITY REPORT
86 QA
AUDIT REPORT SUMMARY
87 QA
AUDIT SCHEDULE & STATUS
88 QA
INSPECTION REPORT
89 QA
SUMMARY OF NCR’s
90 QA
AGEING ANALYSIS OF NCR’s
91 PLANNING
CONTRACT REVIEW
92 PLANNING
MONTHLY PROGRESS REPORT
93 PLANNING
LIST OF MATERIAL
94 PLANNING
REVIEW OF BULK MATERIAL
95 QA
DOCUMENT CHANGE NOTE
96 PLANNING
MONTHLY PERFORMANCE REPORT
97 PLANNING
ACE Vs P&M DEPLOYMENT
98 PLANNING
CUSTOMER SATISFACTION REPORT
99 ALL DEPTS
FILE LIST
100 PLANNING
CUSTOMER COMPLAINT RGISTER
101 PLANNING
CONSTRUCTION DRAWING RECEIPT &
ISSUE REGISTER
Page 76 of 76

QA System KMC AS7

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Widening and strengthening of existing National Highway from 2

lane to 4 lane from km. 1040.300 to km. 1013.000 of NH-31 in

KMC CONSTRUCTIONS LIMITED

VINAY KUMAR UPADHYAY, (Senior Project Manager)

DATE 31 May 2006

Sl.No. Contents Page

QUALITY MANAGEMENT SYSTEM MANUAL

Construction Methodologies and QA/QC Procedures / Inspection &

All the necessary changes and comments, if any, by Client / Engineer

REVISION RECORD SHEET

Sl. Reference Old Rev. New Rev. Detail of Revision

QAM - QUALITY ASSURANCE MANUAL

ITP - INSPECTION AND TEST PLAN

SCI - SECTION INCHARGE

NCR - NON-CONFORMITY REPORT

MIS - MANAGEMENT INFORMATION SYSTEM

ACE - ACCEPTED COST ESTIMATE

JCR - JOB COST REPORT

P&M - PLANT & MACHINERY

MTC - MANUFACTURER’S TEST CERTIFICATE

MRN - MATERIAL RECEIPT NOTE

RFI - REQUEST FOR INSPECTION

Reference and Applicable Documents

Drawings and specifications prepared by consultants.

Major Activities in brief are:

 Repair and Maintenance Works.

Length of Project Road From Patacharkuchi to Kaljar (Total 27.30 Kms)

Contract Package No. EW-II (AS-7)

Employer National Highways Authority of India.

Engineer BCEOM - STUP - AARVEE (JV)

Contractor KMC Constructions Ltd.

Date of Notification for

Contract Period 30 months

New Carriageway 2 laned rigid pavements.

Existing carriageway 2 laned flexible pavements.

Major Bridge 1 No at KM 1025.500

Technical Specifications MOSRT&H Specifications for Road & Bridge Works

Performance Security 10% of the Contract Price

Dispute Settlement Disputes Review Board, Arbitration Process

Amount of Liquidated damage 1/2000 of contract price per day.

Limit Liquidated damage 10% of the Contract Price

Scope of Works (as per BOQ) :

Bill No 1 Site Clearance And Dismantling 2,417,024 INR

BC 751.94 Excavation 185.98

Embment. 567.15 WMM 861.00

Hume Pipe Culvert - - - -

4.0 TERMS AND DEFINITIONS

Client - NATIONAL HIGHWAY AUTHORITY OF INDIA

Procedure – A documented description of the method to be adopted in the performance of a given

5. QUALITY ASSURANCE SYSTEM

Quality Assurance and Quality Assurance Manual

It should generally cover the following:

(b) Internal QA system of each party.

(d) Organization of personnel, responsibilities and lines of reporting for QA purposes.

(f) Inspection at the end of defect liability period.

(g) Items to be covered in maintenance manual.

(h) All formats for documentation.

Quality Assurance Manual for Highways/ Roads

Various activities on a road project can be classified under three groups.

Manufacturing activities fall under the following two categories.

Typical Quality Assurance Plan For Design And Construction

 Q.A. procedure for setting out of works and temporary works.

 Traceability and product identification (if required by clients).