You are on page 1of 107

Table of Contents

Description Page No.


AMENDMENT RECORD SHEET ________________________________________________
DISTRIBUTION LIST OF CONTROLLED COPIES _________________________________
SECTION 1 - QUALITY SYSTEM _______________________________________________
1.0 PROJECT QUALITY ASSURANCE/QUALITY CONTROL POLICY _____________ 4
2.0 QUALITY SYSTEM _____________________________________________________ 6
2.1 Control Of Documents, QA/QC Plan & QA/QC Procedures ____________________ 6
2.2 Control Of Q.C. Records ________________________________________________ 7
2.3 Submittal and review procedure of documents 8
3.0 RESPONSIBILITY, AUTHORITY AND COMMUNICATION ____________________
3.1 Organization _________________________________________________________ 15
3.2. Authorized Representative ______________________________________________ 15
3.3. Levels of Responsibility ________________________________________________ 15
4.0 RESOURCE MANAGEMENT ____________________________________________ 26
5.0 PRODUCT REALIZATION ______________________________________________ 27
5.1 Planning of Product Realization __________________________________________ 27
5.2 Customer Related Processes_____________________________________________ 27
5.3 Design and Development _______________________________________________ 27
5.4 Purchasing and Subcontracting __________________________________________ 27
5.5 Control and validation of Production and Services Provision ___________________ 28
5.6 Identification and Traceability ___________________________________________ 29
5.7 Control Of Customer Property ___________________________________________ 30
5.8 Preservation of Product ________________________________________________ 30
5.9 Control of Monitoring and Measuring Devices ______________________________ 32
6.0 MEASUREMENT, ANALYSIS AND IMPROVEMENT
6.1 Internal Audit ________________________________________________________ 33
6.2 Monitoring and Measurement of Processes _________________________________ 34
6.3 Monitoring and Measurement (Inspection And Testing) ______________________ 34
6.4 Control Of Non-Conforming Product _____________________________________ 34
6.5 Analysis of Data ______________________________________________________ 35
6.6 Corrective And Preventive Actions _______________________________________ 35

SECTION 2 QA/QC PROCEDURES


1.0 Civil Works 35
2.0 Handing over the completed works 55
SECTION 3- INSPECTION AND TEST PLAN 58
ANNEXURES :-
I. QA/QC Organisation Chart 63
II. Temporary works procedure 64
III. List of authorised signatories 76
IV. QA/QC Report forms 78
V. List of major contractors and suppliers 101
VI. Project Qulaity Objective 103

Rev.00
QA / QC Program World One Project

AMENDMENT RECORD SHEET

Section Revision
Amendment Details Date Of Issue Issued By
No. No.

A
Distribution list of controlled copy

Controlled Copies of this document will be distributed as per the Distribution List
available with the QA/QC General Manager, which will be maintained up-to-date.

All Key Project Staff having direct responsibility identified in this Plan will be
issued with Controlled Copies.

Master Copy of this document will be maintained by the QA/QC General Manager.

Controlled Copy No. ______ Issued To : _________________________

The registered holders of this manual must incorporate any amended section of this
manual immediately on receipt.

This QA/QC Manual, with revision number and effectively date shown in the
Amendment Sheet, and any subsequent revision(s) hereto, shall be used and
implemented throughout the execution of this contract and shall serve as the
governing guideline for on-site QA/QC activities.

Any revision to this QA/QC Manual shall be approved by the QA/QC Manager and
concurred to by the Project Director and shall be issued to all Controlled Copy
Holders. However, for amendments or revisions, which do not have any bearing on
the Policy, Procedures, Inspection and Test Plan and Control Forms, revisions will be
notified to the concerned Controlled Copy Holders only. (E.g. Issue of additional
copies or correction of minors typographical errors, which do not reflect any changes
to the contents of the document)

Prepared: Concurred: ______________

Senior QA/QC Manager Project Director


LODHA LODHA
QA / QC Program World One Project

LODHAs Quality Policy

The Quality Policy of Lodha Developers Pvt. Ltd is as follows

i) Lodha resolves to achieve excellence in all fields of Real Estate Business of


clients of Lodha Developers Pvt. Ltd . in accordance with requirements and needs of
clients.

ii) Lodha Developers Pvt. Ltd will carry out all activities while adhering to highest
standards of quality, whilst meeting the applicable Statutory and Regulatory
requirements.

iii) Lodha Developers Pvt. Ltd. will create awareness among all group members to
know and understand the requirements of Quality and ensure that these requirements
are implemented.

iv) Lodha Developers Pvt. Ltd. would achieve these objectives by Selecting
Materials, Group Members and Execution Methods with an emphasis on total
implementation of Quality Policy, while ensuring active participation of all Group
Members to improve the Quality System.

Page 1
QA / QC Program World One Project

LODHAs Quality Objectives:

Quality objectives of LODHA group are as follows

i ) Sustained Quality of all activities of construction to meet clients satisfaction


and needs non conformance not to be exceeding 5 per cent.

ii ) By providing training of 3 man days/year to all key technical staff.

iii ) Wastage of material should not be more than 5 per cent.

iv ) Time management of projects Improvement of at least 5 per cent of the


time compared to customer requirements, keeping track of all the delays due to
all with a view to try to avoid them in future.

Page 2
QA / QC Program World One Project

Section 1

Quality System

Page 3
QA / QC Program World One Project

1. Project Quality Assurance/Quality Control Policy

It is the policy of LODHA GROUP to provide a consistent level of work


performance that meets or exceeds the quality standards set forth in this
manual. Quality is herein defined as conforming to the requirements and
specifications cited within this manual in all matters of construction,
fabrication, and materials procurement control.

With regard to the project WORLD ONE the program set forth in this
manual in conjunction with LODHAs Quality Management Manual becomes
the mandatory, specific vehicle of enforcing the policy of LODHA on the
project.

The QA/QC Manual is established to ascertain that all construction activities


are performed and are in complete conformance with the approved construction
drawings and all applicable standard, specifications and requirements.

The overall responsibility to maintain the program rests with the General
Manager Quality Assurance/Quality Control and his delegated
Managers/Engineers. Their direct responsibility is to ensure that all
Contractor/Employer requirements for this project, together with the integral
QA/QC Procedures and QA Plan are strictly adhered to. The QA/QC
Department is authorized to stop any work/activity until compliance with the
manual is achieved.

The General Manager QA/QC, in his exercise of all functions controlling


quality of construction, fabrication, erection, materials, and test procedures,
shall not be overruled by any Superintendent or Manager, including the Project
Director. Any disputes or conflicts shall be brought to the attention of the
Chief Operating Officer.

Page 4
QA / QC Program World One Project

LODHA shall cooperate and coordinate with contractors/sub-contractors in all


matters relative to the quality control program, and all personnel directly
involved in this project shall be continuously kept informed of project
requirements as work progresses.

This Quality Assurance/Quality Control Manual is binding on all LODHA


personnel and shall be followed without deviation.

Date: _____________________ ____________________________

Kishore Kumar Tidke


Chief Operating Officer

Page 5
QA / QC Program World One Project

2. Quality System

2.1 Control Of Documents, QA/QC Plan & QA/QC Procedures

a. This manual shall be used as reference throughout all phases of construction.


The QA/QC Engineer shall track construction activities and determine when it
is necessary to conduct inspections, arrange for testing, exercising control and
documentation of all inspections made.

b. Should this manual need an update to incorporate additional items not


originally covered, the manual will be "revised" and a corresponding number
assigned. Such revision needs to be concurred with the QA/QC General
Manager. The updated/-revised issue shall then take control and supersede
older provisions. The issuance shall be strictly controlled by the QA/QC
General Manager to ascertain that only updated, revised and governing
documents are in the possession of the concerned parties. A log of approved
manual receivers shall be maintained. Revisions to the manual shall be issued
only to approved holders.

c. Should incharge QA/QC Engineer see a need for a special procedure(s) to


"specialized portions" of the work where same is not available in the list of
approved procedures or method staterment, he shall submit in writing a
proposed QA/QC procedure. The proposal shall address all requirements to the
specific work including procedures, inspections and testing, and the approval of
performing personnel.

d. LODHA will audit the Quality Management System of the contractor/sub-


contractor as per the the requirements in ISO 9001: 2008.

e. A log of deficiencies reflecting QA/QC activities shall be maintained and


monitored on site. All outstanding deficiencies shall result in a non-
conformance report (NCR) being issued to the Project Manager for corrective
action. Appropriate actions shall be taken (see Section 1 - Policy and Section
Page 6
QA / QC Program World One Project

6.4 - Control of non-conformancing product). Accompanying results shall be


logged in accordance with Sections 6.4 of this manual.

2.2 Control Of Q.C. Records

The QA/QC Department shall establish and maintain the following records and files.
It shall be his responsibility to see these records are properly maintained and stored
after project completion and that each of the subcontractors (if any) on this contract
establish and maintain similar records:

a. A record of all tests at frequency mentioned in approved Inspection and Testing


programme including but not limited to the following shall be controlled and
properly documented.

All materials to be incorporated into the permanent construction, including,


cement, steel, couplers, concrete, doors, windows, cladding materials etc.

A reference grid map and layout plan to show location of tests shall be
provided. This will be in addition to the QA/QC test forms submitted
seperately.

b. A file for Daily Q.C. Reports and Monthly QA/QC Reports .

c. A file for maintaining the record of all technical approvals filed consecutively
by submittal number and index. This file shall also include the Technical
Submittal Checklist Form for all technical submittals.

d. A file of current and governing specifications, variation orders, shop drawings


and technical standard raised by the contractor. A document control clerk on-
site will log and track the latest governing data & drawings and ensure proper
issuance of same.

e. A file of operations and maintenance manuals for Contractor-furnished


equipment (if applicable).

Page 7
QA / QC Program World One Project

f. A file for signed off Inspection / Test Records.

g. Contract materials receiving report file.

h. A Record/documentation file of properly logged non-conformance reports


(NCRs) to be used for future reference and evaluation purposes.

i. Manufacturer test certificates with batch number

j. Approved mix designs.

The above QA/QC documentation shall be in the English language and of legible
quality for easy processing/reproduction.

2.3 Submittal and review procedure of documents.

a) Inspection Request (IR)

Inspection request in the approved format with all required attachments should
be submitted to the LODHA group 24 hours in advance. Validity of IR will be
48 hours. Inspection request after processing will be sent back to the contractor
within 48 hours with Lodhas comments and approval status. Code-1 or 2 status
is required proceed with further activity. For taking over any area from the
contractor all relevant IRs should be in code -1 or 2 status.

b) Test Report Submittal (TRS)

Results of all tests conducted as per project requirements should be submitted


to Lodha. Results will be reviewed and sent to the contractor within 5 days.
For taking over any area from the contractor all relevant test report submittal
should be in code-1 or 2 status.

c) Shop Drawing submittal (SD)

Detailed shop drawings for specified construction activities should be


submitted to Lodha well in advance. The shop drawings in AutoCAD should be

Page 8
QA / QC Program World One Project

submitted in prescribed shop drawing submittal format for Lodhas approval.


No activity at site will be allowed without a shop drawing approved in code-1
or 2. Shop drawings will be reviewed by Lodha and returned to the contractor
within 15 days. The maximum number of shop drawing that can be submitted
in each trade per week is limited to 30 nos.

d) Method statement (MSS)

Method statement for all activities should be submitted to Lodha well in


advance. No activity at site will be allowed to be carried out at site without
approved method statement. Method statement will be reviewed by LG and
returned to the contractor with comments within 7 days from the date of
submission.

e) Material Submittal (MS)

All material incorporated into the permanent construction should be approved


by Lodha. Details of materials with source, mill test certificates, previous test
results etc. should be submitted to LODHA group. for review and approval. All
material submittal will be returned to the contractor within 7 days period.

f) Non Conformance Report. (NCR)

Non conformance report (NCR) is incorporated in the system to identify the


deviations from standard construction practice and procedures resulting in non-
compliance of the final product with the required level of quality.

Through NCR, the reason for occurrence of non-conformance will be analysed


and necessary corrective and preventive measures actions will be taken.

Upon receiving the NCR contractor should acknowledge the NCR, explain the
reason for occurrence and propose the corrective action. After obtaining the
approval of corrective action from Lodha, it can be implemented at site. Once
the corrective action is completed it should be sent to Lodha for close out.

Page 9
QA / QC Program World One Project

Once an NCR is issued it should be replied within 7 days and closed out within
30 days.

All relevant NCRs should be closed out prior to hand over any area to Lodha.

Full payment for any activity will be released only after closing out relevant
NCRs.

g) Request For Information (RFI)

Any discrepancy between contract documents if present should be clarified


prior to start any activity. Request for information to obtain necessary
clarification should be submitted to Lodha. The RFI will be replied within 5
days.

h) Document Submittal (DS)

Any document not covered in the above submittal categories can be submitted
as document submittal. Document submittals will be reviewed and returned to
the contractor within 7 days.

Note:- Any document which need to be sent to consultant for their comment may not
be returned to the contractor within the time mentioned above.

For detailed documentation procedures please refer project documentation


plan.

Page 10
QA / QC Program World One Project

Page 11
QA / QC Program World One Project

Page 12
QA / QC Program World One Project

Page 13
QA / QC Program World One Project

Page 14
QA / QC Program World One Project

3. Responsibility, Authority and Communication

3.1 Organization

The Project QA/QC Organization is depicted in the enclosed chart (Annexure I ).

3.2. Authorized Representative

The QA/QC General Manager is the authorized representative of LODHA on all


quality control related issues. He is responsible to interface with LODHAs project
management representative(s) and contractor authorized representative(s) for all
matters pertaining to the Q.C. Program.

3.3. Levels of Responsibility

Project team

Outline Lodha Place team responsibilities:

General:

Develop the construction and package programmes for the works including the
proposed period before commencement of construction work. Detail the major
construction elements, the commissioning and key dates.

Planning of and management of construction activities on site.

Planning of and operation of the security and logistics activities.

Management of the production of Operations & Maintenance Manuals and as-built


drawings.

General Manager Construction:

Liaise and monitor with Statutory Authorities for construction related issues.

Work with Construction Manager and SPM to produce and update all stages of
programme information and monitor production against the planned output

Page 15
QA / QC Program World One Project

Assist the SPM in leading the Project Team to insure that the project objectives are
achieved.

Develop the construction and logistics strategy in conjunction with the SPM

Manage buildability

Instigate and monitor short term programme production and ensure its
implementation

Monitor progress and assist in preparation of reports

Review progress with all Trade Contractors

Implement and manage, with the Commercial Manager, the Project Risk Schedule

Report to and support the SPM

Ensure that the works are constructed in accordance with the relevant drawings and
specification

Day to day liaison with the adjoining owners and other interested parties to minimise
the impact of the project works

Implementation of the Good Neighbour

Motivation of Trade Contractors and short term planning with them to achieve the
required production

Agree sequence, methods, storage and method statements

Implement Quality Management system

Implement and ensure day to day compliance with the Safety Management System,
other Health and Safety requirements

With the appropriate Safety Manager call and chair regular safety and progress
meetings with the Trade Contractors

Ensure that a high level of site welfare and cleanliness are maintained throughout the
project

Manage the provision of all necessary temporary works

Page 16
QA / QC Program World One Project

Monitor and control site security

Management and control of site logistics.

In conjunction with the Project Director and planner, produce and monitor long,
medium and short-term programmes for the works

Assist the Project Director in leading the Project Team to insure that the project
objectives are achieved.

General Manager QA/QC (Off site)

The QA/QC General Manager is responsible for developing the QA/QC Plan for the
project, in compliance with the project specifications and requirements. He shall be
responsible for ensuring that the approved QA/QC Plan is effectively implemented in
the Contract and the inspection and test results are properly documented. He shall
conduct audits to ensure compliance of the construction activities in compliance with
the approved Method Statements and QA/QC Plan and verify that Quality Records
are being documented accordingly.

He shall review all modification and amendments to the QA/QC Plan, as listed under
Section 2.1.

Senior QA/QC Manager

Prepare Quality Control Plan for the project and ensure its implementation.

Leading the team of QA/QC Engineers and inspectors.

Review QA/QC Plans from contactors and issue approval.

Monitor performance of sub-contractors on quality of work.

Recommenda the acceptance of works by other contractors with respect to contract


specifications and carry out tests prescribed in the contract.

Arranging and monitor inspection process.

Monitor testing of materials and reviewing the results.

Documentation of pre-construction quality records.


Page 17
QA / QC Program World One Project

Advise Project Director on QA/QC matters when disputes arise with other
contractors.

Initiate and follow-up Non Conformance Reports and discrepancies till close out.
Investigate the root cause of Non-Conformances and suggest corrective and
preventive measures.

Work closely with the Project Director/GM-Projects to ensure that all material
submittals, method statements and other submittals are prepared, verified and
approved.

Ensure that all materials and equipment incorporated into permanent construction are
in compliance with the project requirements.

Maintain Quality records related to the project in a manner, which ensures proper
identification, traceability and easy retrieval.

Follow up on Close-out of projects in coordination with Project Director.

Provide support to QA/QC Engineers in preparing the documentation, maintenance


and submission of Contract Inspection and Testing packages and verify their
adequacy prior to submission.

Assistant Manager QA/QC

Shall be under the direct supervision of the Senior QA/QC Manager.

Shall arrange for inspections; monitor the required tests and record inspections and
tests made. In the inspections, he shall ensure compliance of construction to contract
plans and specifications and the attainment of quality level as work progresses.

Responsible to ensuring that all material and non material submittals, method
statements and other submissions are prepared, verified and submitted in compliance
with the project specifications and that the documentation meets the requirements of
contract specifications.

Page 18
QA / QC Program World One Project

He shall coordinate with the Project Manager regarding works performance. He is


authorized to raise or close out Non-Conformance certificates upon satisfactory
correction of noted deficiencies.

Shall ensure that all materials and equipment incorporated into permanent
construction are in compliance with the contract requirements. He shall ensure that
required factory or supplier compliance certificates have been obtained upon
delivery of available material at the project site.

He will be available to ensure effective implementation of the QA/QC Plan.

Co-ordinate with Site Laboratory and or Independent Testing Agencies to ensure that
all requisite tests as per Project Specifications are conducted and the reporting is
properly done.

Maintain all Quality records identified in this QA/QC Plan and as instructed by the
Engineer/Employer and submit to them as per the required frequency.

Review As-build drawings for comments, as requested by the office / Planning


Engineer prior to final submission.

Prepare the documentation, maintainence and submission of contract test packages.

QA/QC Engineer

Shall be under the direct supervision of the Assistant Manager QA/QC.

He shall arrange for inspections; monitor the required tests and record inspections
and tests made. In the inspections, he shall ensure compliance of construction to
contract plans and specifications and the attainment of quality level as work
progresses

He shall ensure that all materials and equipment incorporated into permanent
construction are in compliance with the contract requirements. He shall ensure that

Page 19
QA / QC Program World One Project

the required factory or supplier compliance certificates have been obtained upon
delivery of available material at the project site.

He will be available to ensure effective implementation of the QA/QC Plan.

Co-ordinate with Site Laboratory and or Independent Testing Agencies to ensure that
all requisite tests as per Project Specifications are conducted and the reporting is
properly done.

Maintain all Quality records identified in this QA/QC Plan and as instructed by the
Engineer/Employer and submit to them as per the required frequency

Review As-build drawings for comments, as requested by the office / Planning


Engineer prior to final submission.

Senior Projects Managers:

Assist the General Manager in leading the Project Team to ensure that the project
objectives are achieved.

Develop the construction and logistics strategy for the Residential Building in
conjunction with the SCM and PM

Manage buildability for the Building.

Monitor implementation of method statements.

Implement safety policies and procedures and the Safety and Environmental
Management System

Instigate and monitor short term programme production and ensure its
implementation

Manage QM, review and update the Project Execution Plan

Deputise for the General Manager in all aspects as listed above in his absence as
required

Supervision and progress of work.

Page 20
QA / QC Program World One Project

Monitor progress and assist in preparation of reports

Interface with contractors on day to day matters and contract administration.

Implement and manage, with the Senior Commercial Manager, the Project Risk
Schedule

Organise and chair regular progress and safety meetings. Agree design programme,
monitor production and quality of design information and manage information
release.

Review design information for compliance with specified requirements and with a
view to value engineering

Senior Project Engineers, Project Managers:

Assist the SPM in leading the Project Team to ensure that the project objectives are
achieved.

Prepare package method statement documents

Manage buildability for the Residential Building.

Implement safety policies and procedures and the Safety and Environmental
Management System

Monitor progress and assist in preparation of reports

Review progress with all Trade Contractors

Co-ordinate and instigate liaison with adjoining and adjacent building

Implement and manage, with the Commercial Manager, the Project Risk Schedule

Organise and chair regular progress and safety meetings with TC.

Project Manager Services

Agree design programme, monitor production and quality of design information and
manage information release for services aspects of the project

Supervision of services activities.

Aproval of shop drawings and method statements for MEP work.


Page 21
QA / QC Program World One Project

Review design information for compliance with specified requirements and with a
view to value engineering

Work with SCM and SPM to produce and update all stages of programme
information and monitor production against the planned output

Monitor and manage installation and commissioning processes to ensure compliance


with specified objectives

Carry out on and off site witness testing with Trade Contractors and consultants

Organise and chair regular progress and safety meetings with services Trade
Contractors and statutory undertakings

Plan, monitor and manage installation and commissioning of new incoming services
to the project

Manage buildability

Monitor progress and assist in preparation of reports

Review progress with all Trade Contractors

Implement and manage, with the Commercial Manager, the Project Risk Schedule

Ensure Quality and Quantity of MEP work.

Senior Commercial Manager/Senior Cost manager

Manage the project finances to ensure it is a commercial success

Protect Lodha Group from financial risks

Identify risks and constraints, and advise options.

Updating and monitor the cost plan.

Establish and implement cost control procedures and documentation

Verification of contractor claims.

Costing of variations.

Verification of tax implications.

Page 22
QA / QC Program World One Project

Monitoring securities.

Co-ordinate cost planning, procurement and commercial management objectives and


activities.

Monitor design and procurement to ensure compliance with cost plan and
programme

Monitor procurement process to ensure best buy

Determine, with the SPM, the procurement strategy and monitor the procurement of
the packages.

Examine and prepare estimates of cost for alternative design solutions, methods of
construction and programmes

Prepare cash flow forecasts as and when required

Co-ordinate and prepare cost on books / forecast final cost report and assist SPM in
production of monthly report

Certification of contractor bills.

Prepare monthly valuations and ensure payments are received promptly

Commercial Manager/Cost manager

Protect LG from financial risks

Identify risks and constraints, and advise options.

Implement cost planning, procurement and commercial management objectives and


activities.

Monitor procurement process to ensure best buy

Examine and prepare estimates of cost for alternative design solutions, methods of
construction and programmes

Recording and checking of measurements.

Co-ordinate and prepare cost on books / forecast final cost report and assist SPM in
production of monthly report

Page 23
QA / QC Program World One Project

Prepare monthly valuations and ensure payments are received promptly

Design Manager

Assist in management of team in terms of milestone deliverables

Call regular meetings with the design team to ensure satisfactory communication/co-
ordination

Establish a design programme with the design team including clear deliverables

Monitor design progress and design to ensure compliance with cost plan and
programme

Track decisions and approvals.

Comment on buildability

Liaise with consultants.

Liaise with SPM and SCM with regard to the Procurement Schedule and
Procurement Strategy.

Senior Planning Manager

Report to and support the SCM.

Develop and maintain overall control of the development programmes and sub
sections forming it.

Liaise with the Design Manager, Commercial Manager, Project Managers and
Construction Managers on progress to date and forth coming items.

Report progress against critical path.

Flag alerts.

Prepare look ahead schedules.

Assist in the development of coordinated Trade Contractor programmes.

Assist in the production of the Trade Contracts.

Assist in the production of monthly reports.

Page 24
QA / QC Program World One Project

Information Manager

Manage the Acconex document control system and its use by all parties

Ensure compliance by all parties of the Acconex project protocol

Issue all necessary notification to Trades of Information available

Training and arrangement of such for use of the system

Page 25
QA / QC Program World One Project

4. Resource Management

All personnel employed in this project and have a direct bearing on the quality of the
construction activities will be selected based on their qualifications, experience and
exposure to the working environment.

4.1 Familiarisation and training

All staff joining this project and having direct bearing on the quality aspects of work
will be formally inducted through training sessions conducted periodically by the
QA/QC Departments. Records of such training shall be maintained by the General
Manager QA/QC.

Refer to LODHA Quality Management Manual, section 6.2.2.

Page 26
QA / QC Program World One Project

5. Product Realisation

5.1 Planning of Product Realization

This refers to Clause 7.1 of ISO 9001:2008 Standard requirements. Refer to


LODHA Quality Management Manual section 7.1 for more details.

5.2 Customer Related Processes

This refers to Clause 7.2 of ISO 9001:2008 Standard requirements. Refer to


LODHA Quality Management Manual, Section 7.2.

5.3 Design and Development

This refers to Clause 7.3 of ISO 9001:2008 Standard requirements.

Where details or drawings are not made available, if required by the Consultant,
LODHA shall propose the design and drawings based on applicable specifications
and relevant industry standards and engineering practices. All drawings prepared
shall be developed through the system with adequate details on design input, design
review, design validation and design verification as per ISO 9001:2008 requirements.
Design drawings developed will be submitted for connsultants approval with back-
up calculations and design sheets.

Development of all shop drawings and As-Built will be done as per approved
Method Statements and in conformance with industry practices and contract
specifications.

In absence of any consultant stipulated specifications for this project, relevant


statutory body specifications and or engineering standards are considered for design
and development of drawings with the approval of consultants.

5.4 Purchasing and Subcontracting

This refere to Clause 7.4 of ISO 9001:2008 Standard requirements.

Page 27
QA / QC Program World One Project

a. All Purchasing activities shall be done as per the Material Purchase Procedure
in the LODHA Quality Manual. All subcontracting activities will be as per
LODHA Quality Management Manual Section.

b. Subcontractors hired by LODHA to perform specific portions of the work,


which are detailed within the sub-contract agreement, shall conform to the
requirements of the QA/QC Plan. For this purpose, the subcontractors for all
major subcontracts are required to submit to LODHA, a QA/QC Plan, in
conformance with LODHAs QA/QC Plan. This Plan will be duly reviewed
and approved by the LODHAs General Manager QA/QC.

c. The Subcontractor QA/QC Plan shall be in a similar format to that of LODHA


QA/QC Plan and shall identify Inspection and Test control points (witness,
review, hold etc.) for LODHA. All the Control/Inspection Records of the
Subcontractors shall include approval provision for LODHA Engineer. All
quality records relating to the subcontract work shall be submitted to LODHA
for approval.

d. Designated LODHA QA/QC personnel shall oversee subcontractor compliance


with the QA/QC Plan and audit the subcontractor as necessary compliance.

5.5 Control and validation of Production and Services Provision

This refere to Clause 7.5.1 and 7.5.2 of ISO 9001:2008 Standard requirements.

All Contract specifications for this project, alongwith relevant statutory body
specifications and or relevant engineering standards are considered for execution of
the project and effective quality control. Where a requirement is specifically
stipulated by the Engineer during the design and or execution phase of the project,
such instructions will be considered as superceding the relevant specifications.

Page 28
QA / QC Program World One Project

The control of the construction process will be done through the Inspection and Test
Plan QA/QC Procedures in Section 3 and QA/QC Forms.

All the process control procedures and inspection and test points have been identified
in these sections.

5.6 Identification and Traceability

This refere to Clause 7.5.3 of ISO 9001:2008 Standard requirements.

Being a civil construction project involving reinforced concrete construction,


masonry works, finishing works, interior design works, MEP works, landscaping
works, piles and pilecap, earthworks etc., most of the products and materials used in
construction can not be identified individually. Therefore, the product identification
and traceability of materials used in the process is limited to identification of various
construction material and the locations where they have been used through
documented records only. Electrical and mechanical items which can be identified
individually, will be tagged as per Project Specifications and relevant industry
standards. Cement used for the production of concrete for any structural member can
be identified from concrete delivery notes, concrete pour records and relevant mill
test certificate of the cement corresponding to that particular period.

All other items (excluding materials used in a process and can not be separately
identified on completion of the process, e.g., cement in concrete etc.) procured for
this project will be identified by the Contract No. and Purchase Order No. During the
process of receipt, storage, and issue, this will be supplemented by relevant quality
documents such as test certificates, mill certificates, certificate of compliance to
specifications and reference standards etc.

An identification procedure shall be maintained for all materials, parts and


components, including partially fabricated assemblies. Traceability shall be
maintained on equipment, materials, parts and components, as required by the
standards and specifications. Identification of an item shall be addressed either by
using tags, stamps, color-coding, stencils or labels or by records traceable to an item
Page 29
QA / QC Program World One Project

throughout fabrication, erection, installation, repair, modification and use of the


item.

The location and the method of identification shall not affect the function or quality
of the item being identified. The procedure shall require that verification of correct
identification of material, parts and components be made and documented prior to
installation.

Material not in compliance with these requirements shall be rejected, segregated and
then physically removed from the work within 24 hours of being rejected.
Confirmation that the material has been removed shall be made by the LODHA
QA/QC Engineer.

Measures shall be established to identify inspection and test progress. Such measures
shall provide means for ensuring that required inspection and tests are performed
during each phase of the construction activity and during installation . It shall also
ensure that the required resources are available to meet the work schedule and thus
the status of the inspection and test work is known throughout execution of the
project.

5.7 Control Of Customer Property

This refere to Clause 7.5.4 of ISO 9001:2008 Standard requirements.

This clause is not applicable for this project, since there is no Customer supplied
products.

5.8 Preservation of Product

This refere to Clause 7.5.5 of ISO 9001:2008 Standard requirements.

All material deliveries to the site shall be inspected and checked by the concerned
QA/QC Engineer to ensure the materials are not damaged or in anyway defective and
are in conformity with the material approvals, purchase orders, and packing lists. If

Page 30
QA / QC Program World One Project

discrepancies are found, they will be reported to the Head of purchase department,
through the Project Manager, who in turn shall notify the vendor concerned.

Materials found acceptable will be stored in a manner appropriate for the particular
type of material or in accordance with the manufacturer and/or supplier's
recommendations. The Field Engineer and or the QA/QC Engineer shall ensure
compliance.

The following storage guidelines shall be implemented by the warehousing staff:

1. All materials should be manufactured as per manufacturer specifications.


Materials to be stored under controlled temperature conditions should be
stored in airconditioned containers. Only limited quantity of materials with
limited shelf life should be stored at site.

2. Stacked items shall be suitably protected from damage by spacers or load


distribution supports and shall be safely arranged. No metal work shall be
stored directly on the ground. Items shall be stored so that they are not
subjected to excessive stresses and that the protective coatings and finishes
are not damaged.

3. Mechanical/Electrical equipment & fittings shall be stored in labelled racks


or store rooms and shall be arranged and labeled to facilitate retrieval for use
in a programmed order.

4. All materials stored outside that may deteriorate or may be damaged as a


result of direct exposure to the weather, like steel rebar, wood, and cables
shall be adequately covered or protected as recommended by Manufacturer.

5. Machine surfaces shall be protected with cover discs.

6. Hazardous materials should be stored separately and should be able to


identify quickly so that it is used for indented purpose only. Sufficient

Page 31
QA / QC Program World One Project

warning symbols should be exhibited near the storage location of such


materials.

5.9 Control of Monitoring and Measuring Devices

This refere to Clause 7.6 of ISO 9001:2008 Standard requirements.

All the Inspection, Testing and measuring equipment will be calibrated to relevant
specifications and statutory requirements. Only those instruments having current and
valid calibration certification or identification will be used for inspection, test and
measurement purposes.

A Master Log of all calibrated equipment showing the equipment details, frequency
of calibration, last date calibrated, reference standard, location, identification number
and agency that performed calibration shall be available at the Laboratory for
verification.

Page 32
QA / QC Program World One Project

6. Measurement Analysis and Improvement

6.1 Internal Audit

This refere to Clause 8.2.2 of ISO 9001:2008 Standard requirements.

An internal Audit in the field shall be performed to verify quality control activities
are in accordance with written procedures and general provisions. The audit shall
include but not limited to:

Inspection and Test Reports

Material Tracking

Document Control Records

Test Equipment Calibration Records

Daily Reports

The Designated QA/QC Personnel on site shall perform a continuous audit on a day
to day basis reporting any non-conformities in application of the QA/QC Program to
the QA/QC Manager.

The Designated QA/QC Personnel shall investigate corrective procedures within his
term of responsibility or inform the QA/QC Manager accordingly for further action.

The QA/QC Manager, Project Manager, and LODHA internal Audit team shall
perform audits as per LODHA Quality System Internal Audit Schedule.

Random audits shall be performed at any time especially when circumstances


change, such as major changes in the QA/QC Program, new personnel, and to verify
corrective actions are properly performed and documented.
Page 33
QA / QC Program World One Project

6.1.1 Audit Procedure

Audit shall be carried out according to checklists previously prepared to suit each
particular case and activity or facility to be audited. A report shall be issued on
completion of each audit giving a summary of the findings and recommendations for
corrective action if necessary.

When corrective actions are recommended, the time limit for their implementation
should be stated. The activity concerned should be audited again at the expiration of
the time limit to verify correction of the identified non-conformance.

Audit report forms and checklist forms are prepared as per ISO 9001:2008
requirements.

6.2 Monitoring and Measurement of Processes

This refer to Clause 8.2.3 of ISO 9001:2008 Standard requirements.

Refer to LODHA Quality Management Manual, Section 8.2.3

6.3 Monitoring and Measurement (Inspection And Testing)

This refere to Clause 8.2.4 of ISO 9001:2008 Standard requirements.

6.4 Control Of Non-Conforming Product

This refere to Clause 8.3 of ISO 9001:2008 Standard requirements.

QA/QC Department shall implement procedures to prevent inadvertent use of procedures,


material, parts, components, services, or workmanship not conforming to requirements of
the contract, codes and specifications per the requirements of ISO 9001 series. Procedures
shall include closed-loop control for the identification and documentation of non-
conformances, corrective actions and waivers of contract requirements.

Non-Conformance Reports (NCR's) issued by the QA/QC Department, Sub-Contractor,


Vendors, Manufacturers and Suppliers shall be copied to the relevant personnel to document
specific contract scope, standard and specification violations being observed.
Page 34
QA / QC Program World One Project

QA/QC Department shall investigate the causes of non-conforming items, and initiate
corrective actions to prevent reoccurrence of non-conformities.

Repair and rework items shall be re-inspected in accordance with applicable procedures.
Controls to restrict further processing or installation of a non-conformance or defective item,
pending a decision on its disposition, shall be established and maintained.

All non-conformance reports shall be documented on an Non-Conformance Report Log,


which is to be submitted by the QA/QC Engineer at the regular progress meeting.

Detailed QA/QC Procedure for Non-Conformance's are given in Section 3 / 3.3

6.5 Analysis of Data

This refere to Clause 8.4 of ISO 9001:2008 Standard requirements.

LODHA group employs various management tools and techniques to review and analyse
data which have an impact on the production, planning, quality and cost aspects of a
contract. ACC will identify the need for any statistical techniques for improving the
productivity and analyzing problem areas for corrective and preventive actions.

6.6 Corrective and Preventive Actions

This refere to Clause 8.5.2 and 8.5.3 of ISO 9001:2008 Standard requirements.

a) Corrective Action

The Non-Conformance Procedure under Section 3 describes in detail the procedure for
identifying the corrective actions and performing them to resolve a non-conformance.

b. Preventive Action

Following the identification of a Quality System failure (or potential failure) during any
phase of the construction activity, as identified through Non-Conformance Reports,
Discrepancy Register, Employers / Engineers Notifications or Internal Audit Reports, the
QA/QC Manager, alongwith the QA/QC Engineer will initiate an investigation to identify
problem areas revealed and establish preventive methods to minimize the risk of any
possible causes of such events occurring in the future.

Page 35
QA / QC Program World One Project

All required actions, both for Corrective and Preventive Action, are recorded on the
Nonconformance report attachen in Appendix-IV. Also recorded on each Action required
form is the name of the person responsible for carrying out the action and its completion
date. Brief details of each action required are recorded on an Action Required Log Sheet.

Following the agreed completion date, a check will be made to verify that the corrective
action has been implemented and appears to be effective and efficient. Refer to ACC
Quality System Procedures Manual, Procedure QSP-8.06 for more details.

Page 36
QA / QC Program World One Project

Section II

Quality Control Procedures

Page 37
QA / QC Program World One Project

1. Civil works:

R.C.C. Structure.

World One is a framed structure with a raft of 5 meter thickness for the
foundation. There are 2 basement slabs, followed by 6 podium slabs and
structural slabs at higher levels followed by the roof slab.

This section outlines the requirements for concrete work for all structural elements is
project

This part included selection of materials for the production of concrete, approval of
ready mix supplier, procedures for placing and curing concrete, post pour checks and
taking over the completed works.

Concrete of different grades for each structural element shall be as per design
requirement from consultant.

Mix design for each mix prepared by ready mix supplier and approved by M/s
LODHA GROUP shall be used in this project.

Only ready mix concrete shall be used in this project for all structural elements.

All ingredients for the production of concrete shall be as per the approved mix design
and quality plan submitted by the supplier and approved by M/s LODHA GROUP.

Rebar for the production of RCC should be from the approved source. Physical
mechanical and chemical tests should be conducted for every hundred tonnes for
each dia. of steel from each source.

Storage of aggregates for the production of concrete shall be as per IS 383

Facilities for pumping concrete should be from competent agencies approved by M/s
LODHA GROUP.

Concrete should be poured within three hours from batching time.


Page 38
QA / QC Program World One Project

Tests on aggregates and fresh concrete will be carried as per approved ITP

Placing concrete shall be as per IS 4926 and IS 456 and approved method statement.

Concrete shall not be poured from a height of more than 1.5m.

Any addition of water to concrete at site is not allowed.

Concrete temperature at the timing of pour should not be more than 250C for massive
concrete elements and 32oC for non-massive concrete elements.

Heat of hydration and temperature differential within the massive concrete elements
will be monitored by placing loggers in the elements as per approved layout.

Additional cubes will be cast for slabs to determine strength of concrete to facilitate
early removal of shutters.

Removal of shutters will be permitted only when the cubes attain 70% of design
strength.

Curing of concrete elements shall be carried out for a period of minimum 12 days.
For massive concrete elements controlled curing shall be adopted to prevent faster
cooling of outer surface which increases the temperature differential between
concrete core and outer surface. For elements cast with high performance concrete,
curing should start immediately after concrete hardens to minmise the loss of
moisture from concrete. Curing of concrete should be continued for the entire period
so that desired results are achieved. Correlation in concrete strength should be made
with specimens cured in water tanks and specimens cured by applying curing
compounds.

Tests on hardened concrete should be carried out as per IS 516

Page 39
QA / QC Program World One Project

Page 40
QA / QC Program World One Project

Page 41
QA / QC Program World One Project

Page 42
QA / QC Program World One Project

Block Masonry work

This section outlines the requirements of masonry works to be done in this project

This part included selection of materials for production of masonry walls, post
construction checks and taking over the completed works.

Materials used for masonry works should be approved by Lodha group.

Necessary field tests will be carried out prior to accept the brick/ block. Replacement
of OPC by fly ash shall be done with the approval of Lodha Group. When other
cementitious materials are used mixing of mortar shall be done in mechanical
mixers. Mortar shall be brought to the site in wheel barrows and unloaded on MS
trays.

Approved water cement ratio is to be maintained and after mixing mortar should not
show excess bleeding.

No addition of water to mortar is allowed at site.

Prior to start masonry work layout of masonry walls should be clearly marked. The
RCC surface in contact with masonry should be scabbled properly.

Any porous surface on which mortar is placed for masonry work should be fully
saturated.

Joints between RCC structural members and masonry walls should be filled properly.

In a days work masonry wall should not be constructed for more than 1.2m height.

Next day a RCC band of 100mm thickness with M15 grade concrete and 2nos 8mm
dia. bars connected with open links should be cast on the 100 thick walls.

Mortar joints between bricks/blocks should be raked for a depth of 10mm with the
help of raking needle.

Page 43
QA / QC Program World One Project

Curing of the walls should be carried out for a period of 10 days.

Plastering work

This section outlines the requirements of plastering works to be done in this project

This part include selection of materials for preparation of mortar for plastering
works, post construction checks and taking over the completed works.

Materials used for plastering works should be approved by Lodha group.

Mortar to be used for plaster should have a minimum strength of 3.5 MPa.

Addition of water to mortar at site is not allowed.

It is recommended to carryout external plastering before starting internal plastering


to prevent rapid drying and shrinkage if internal plaster surface.

Minimum time gap of 7 days shall be maintained between completion of masonry


wall and commencement of plastering work.

The surface to which plaster is to be applied should be free from projecting nails
wooden pieces etc. and should be cleaned properly so that there is sufficient bond
between the masonry surface and plaster.

Thorough wetting of the surface to be plastered is to be done two days prior to start
plastering work.

The day prior to do plastering work it should be left to attain saturated surface dry
condition.

Level pads of size not less than 2 x 2 at maximum interval of 6 in either direction
shall be made on wall and on ceiling, if required, to serve as finished reference level
surface.

If plaster is applied over concrete surface it should be scabbled and cleaned properly.

Page 44
QA / QC Program World One Project

For internal plaster the average plaster thickness shall be 12mm thickness. When the
thickness exceeds 15 mm it should be done in two layers.

External plastering should be done in two layers. Average thickness of first layer
should be 15mm and the second layer thickness.

First layer should be roughened properly to provide sufficient bond between two
layers of plaster.

Chicken wire mesh shall be fixed at the joint of block/brick masonry wall and RCC
structural elements. Chicken mesh shall be 20gauge with 12mm hexagonal holes.

Page 45
QA / QC Program World One Project

Doors and Window.

Frames

Wood used for the production of door and window frame should be approved source.

Wood shall be fully seasoned, crack free and straight.

Wood shall have parallel grain structure and the surface should be dry and without
oil secretion.

Moisture content in wood shall not exceed 14% when checked with moisture meter.

Single section shall not have more than three knots.

Door frames should be of uniform thichness, all members should be straight.

All exposed surfaces of the framew should be planed smooth.

Depth of rebate in door frme shall be minimum 15 mm in door frames and minimum
12mm in window/ventilator frames. Rebates shall be of uniform thickness through
out the length of frame.

Door frames shall be provided with minimum three numbers of holdfast on either
side for door frames with maximum height of 2100mm. For additional height of .
Ends of holdfast shall be split. One holdfast shall be provided in the middle whereas
the other two shall be provided 300mm from top and bottom. For main door frame
minimum four holdfast on either side shall be provided. Holdfast shall be embedded
in M15 grade concrete.Hold fast if required to be fixed to concrete surface , then
they should be fixed by drilling holes in concrete. Coach screw can be used for the
same. Coach screw of approved cross section and length sunk within the frame and
capped by plugging with same timber material.

All door frames shall be applied with primer (for paint) and with multan matti (for
polish) immediately after their receipt at site.

Page 46
QA / QC Program World One Project

Portion of door frame to be embedded in floor as well the face in contact with the
masonry shall be applied with a coat of bituminous paint.

Knee braces for frames shall not be removed unless frame is fixed satisfactorily.

After fixing frames, the enire frame shall be again be checked for plumb, level and
right angle and necessary rectification shall be carried out if required.

Shutters

Door shutter shall be from approved source.

Moisture content shall be checked using moisture meter and should not exceed 12%
as per IS 2202 (Part 1):1999

Timber used shall be well seasoned and without any cracks.

More than three knots per shutter shall not be allowed.

Immediately after receipt shutters shall be applied with wood primer on all sides
including edges.

Lipping patti shall be in teak wood and in one piece. Double lipping patti shall not be
used to increase the door shutter size.

Door accessories

Door accessories like aldrop, tower bolts, door handles, hinges, stoppers etc. shall be
as per specifications.

Test on Door Shutters

A) Dimensional Checks

a) Measurement of length and width

b) Measurement of thickness

c) Squareness
Page 47
QA / QC Program World One Project

d) Twist

B) Steel Ball Impact Test

C) Distructive tests

a) End Emersion Test

b) Glue Adhesion Test

c) Knife Test

In addition to the above, following tests shall be carried out in laboratory for wood
and door shutters.

a) Varying Humidity Test

b) Slamming Test

c) General Flatness Test

d) Shock Resistance Test

e) Edge Loading Test

f) Local plainness Test

g) Flexural Test

h) Bulking Test

i) Screw Pull Out Test

Note :- Details of tests to be conducted and frequency of tests will be as per the
Inspection and Test Plans.

Page 48
QA / QC Program World One Project

Page 49
QA / QC Program World One Project

Tiling, Skirting, Toilet Dado and Kitchen Platform.

Tile, Marble or granite used should be of approved design and from approved source.

Tiles on receipt of every lot should be checked visually for any cracks, chipped
surfaces, colour variation and arrow mark. If tiles are not found satisfactory, the
entire lot of tiles shall be rejected.

Natural stones like granite and marbles shall be checked for any flaws, fissures,
craks and uniformity in colour as well as grain structure.

At least two samples of natural stones for matching with requirements like colour,
thickness and bearing manufacturers label shall be obtained from the suppier for
approval. One approved sample shall be retained at site for acceptance, at the time of
delivery of materials.

Natural stones shall be matched with samples kept at site for colour, uniformity of
thickness, cleavage, soft spots etc.

Italian marble shall be subjected to macroscopic examination for detection of hair


thin cracks not visible to naked eyes but visible after polishing.

Ingradients used for the preparation of bedding mortar for tile fixing shall be as
follows

Cement of 43 grade free from lumps and not more than 8 weeks old shall be used.

If 53 grade cement is used it should be adequately blended with fly ash.

Water used for curing of tiling work shall not contain sulphates more than 0.05% and
chlorides more than 0.1%.

Admixtures like tile adhesive shall be from reputed manufacturers. Care shall be
taken to see that it is compatible with the type/brand of cement being used.
Page 50
QA / QC Program World One Project

Next day after laying the tilesit should be raked with thin metal sheet filled with
grout of matching shade and cured for three days. Use of half round tool shall be
made for filling joints, where spacers are used.

After curing is over, joints of tiles shall be covered with masking tape to prevent
entry of dirt into it and shall be covered with a layer of POP with paper underneath,
for protection against scratches due to dragging of heavy objects over them as als
stains due to dropping of acids, detergents and other heavy objects and foot marks.

Grout of matching colour shall be appkied over the entire space of natural stone
flooring surface to fill up joints and then polishing work is to be carried out as per
the procedure.

Polishing of the natural stone flooring shall be done with designated stones in three
coats.

Natural stone flooring sjhall be protected from stains, weathering effects, detergent
effects etc.

Stain free coating should be applied immediately after intermediate coat of grinding
and polishing work.

Discription of tests and frequency of tests to be carried out are

Laying of tiles, marble and granite shall be carried out as per approved
method statement.

Tiles shall be laid as per the approved lay out/design, if any.

Following tests will be carried out on tiles

Measurement of length and width

Measurement of thickness

Measurement os rectangularity
Page 51
QA / QC Program World One Project

Note :- Details of tests to be conducted and frequency of tests will be as per the
Inspection and Test Plans.

Page 52
QA / QC Program World One Project

Painting works

Paing material should be from approved source, colour etc. as per specifications.

Other materials associated with painting works are primer, putty, thinner, paint
brush, surface finishing roller etc.

Paint shall be thoroughly mixed prior to application. Ensure hat all kinds of civil as
well as electrical works works are completed prior to start painting works.

Minimum 60 days gap should be provided between painting and plastering works.
When sufficient time is not available for the surface of walls to dry out, walls shall
be applied with cement paint or oil free distemper which will allow drying process to
continue at reasonable rate through their film.

In any case glossy paint shall not be applied till the drying process is completed.

No painting work shall be carried out in wet and very humid weather where there is
danger of dure or when weather is unfavourable.

Before applying the paint the surface shall be prepared properly

The surface shall be dry and free from dirt and any loose materials.

If any crack is observed it shall be repaired.

Painting on ceiling should be completed prior to start painting on walls.

Application of paint shall be carried out as per approved method statement.

Acceptance of completed works.

Page 53
QA / QC Program World One Project

Sl.No Type of check Acceptance

1 Brush/roller marks Shall not be observed

2 Dust/Colour patches Shall not be observed

3 Damp spots Shall not be observed

4 Texture Uniform

5 Shade variations Shall not be observed

6 Glue adhesion test Satisfactory

7 Coat thickness Satisfactory

Page 54
QA / QC Program World One Project

2. Handing over to customer care

Taking over the completed areas from contractors

This section outlines the procedure for taking over any completed activity by
LODHA

Once substantial completion of the work for a particular area is achieved joint
inspection of the area will be carried out by LODHA and contractor team and list of
snags will be prepared. All items in the snag list should be completed before
submitting official hand over request by the contractor to LODHA.

Contractor should submit a formal request to Lodha group in prescribed format for
taking over the completed works.

Prior to raise the request for taking over by Lodha,

Work should be completed in all aspects

All relevant IRs should be code-1 or 2 status

All relevant test results should approved in code-1 or 2

All relevant NCRs should be closed out

List of snags should be signed off.

All keys should be handed over to LODHA

All operation and maintenance manual should be submitted to Lodha

All required warranty should be submitted to Lodha

All training manuals should be submitted to Lodha

Once all these procedures are completed Lodha representative will inspect the area.
If all the requirements are satisfied Lodha will officially take over the completed
area.

Page 55
QA / QC Program World One Project

Once LODHA take over the area from contractor and the project director certify that
the particular area is ready for handover, with all relevant documents, tools and keys
the area will be handed over to customer care.

Page 56
QA / QC Program World One Project

Page 57
QA / QC Program World One Project

Section III

Inspection and Test Plan

Page 58
QA / QC Program World One Project

Page 59
QA / QC Program World One Project

Page 60
QA / QC Program World One Project

Annexures

Page 61
QA / QC Program World One Project

Annexure I

QA/QC Organisation Chart

Page 62
QA / QC Program World One Project

Page 63
QA / QC Program World One Project

Annexure - II

Temporary Works Management


Procedures

Page 64
QA / QC Program World One Project

Temporary Works Management Procedures

Purpose

The purpose of this procedure is to ensure that the requirement for Temporary Works
in World One project is properly assessed and thereafter that the Temporary Works
are designed and implemented in a controlled manner

References

- BS 5975 and references therein.

- Control of Temporary works ProcedureTW01

- Memo appointing Temporary works coordinator TWC Form No TW01A

- Memo appointing Temporary works supervisor TWS Form No TW01B

- Temporary works Tracking schedule/Register, Form No TW02 (Remesh)

- Temporary Works Design Brief/Request.

- Temporary Works Risk Assessment/method statement (Various elements).

- Temporary Works Design/Check Certificate, Approval Report.

- Temporary Works - Permit to Load/Strike, Form No TW03.

References

Senior Site Representative: - Project Director/ General Manager/ Senior Project


Manager / Project Manager

Page 65
QA / QC Program World One Project

Temporary Works Co-coordinator (TWC) :- The competent person appointed by the


Contracts Manager to co-ordinate all activities related to Temporary Works on the
project

Temporary Works Supervisor (TWS) :- The site representative appointed by the


Senior Site Representative to assist the TWC on each phase/site teams in Checking
during erection/installation of Temporary Works for compliance with the relevant
design.

Temporary works Designer :- The companies appointed (RMD, SGB & ALUMA) to
be responsible for the Temporary Works Design Function.

Temporary works checkers :- These are competent nominated consultancy


companies appointed to carryout third party checks on all temporary works designs.

Procedures

General

An item of Temporary Works is an engineered solution used to support or protect


either an existing structure or the Permanent Works during construction, or to
support an item of Plant or Equipment, or the vertical sides or side-slopes of an
excavation during construction operations on site.

The Temporary Works may be removed or left in place after the completion of the
permanent works but in the latter case would not necessarily contribute to the
strength of the Permanent Works.

A Temporary Works study may involve an assessment of the Permanent Works


during the various stages of construction, modification or demolition to determine
adequacy of strength and/or stability.

A Temporary Works study may involve an assessment of excavation stability or


necessary supports particularly where the excavation slopes are steep or are
surcharged by other loads.
Page 66
QA / QC Program World One Project

In general, a contract will not require a TWC if excavations are no deeper than 1.2m
and no temporary works, other than normal access scaffolding above ground, are
required.

The Project Director will consider the need for a TWC, and if necessary, will consult
with the Engineering Manager regarding the competence of the person to be
appointed.

The Project Director will be responsible for confirming verbally or in writing the
appointment of a TWC with copies or information being sent to the Senior Site
Representative, Safety Advisor, QA/QC etc.

Where the TWC is absent from site for a significant period the Project Director will
ensure that alternative arrangements are made for checking of the erection of
temporary works by appointing a substitute.

On large sites or where the Senior Site Representative considers it necessary, or


where the TWC requests assistance the Senior Site Representative shall appoint one
or more TWS to assist the TWC in the inspection, during erection, use and
dismantling of the temporary Works.

Where necessary the Senior Site Representative will consult with the Engineering
Manager regarding the competence of the person to be appointed. The appointment
will be in the form of a memo/Email and acceptance received.

Register

The Senior Site Representative, or his nominee, will determine and list the
construction activities, which will require a Temporary Works Design. Further
activities may be added to the list as the contract progresses.

The TWC will prepare a Register for each of the Temporary Works Schemes and
will consider (by reference to the Contract Programme) the dates required for each of
the following:

Page 67
QA / QC Program World One Project

a) Preparation and issue of Design brief

b) Completion of Design

c) Completion of third party Independent check

d) Engineer/Client/third party approval, where required

e) Period for Material/Plant procurement

f) Preparation of Inspection Plan in coordination with QA/QC

g) Permit to Load/Strike Form in coordination with QA/QC

h) Implementation

i) Use

j) Dismantling

The TWC will update the register in conjunction with the document control
department and the Engineering manager will be kept informed.

The design function and third party design checks will be carried out by suitably
qualified personel as approved by the contracts manager.

Design Brief

The TWC shall agree with the Senior Site Representative as to who will be
responsible for preparing the design brief for each Scheme. When preparing the
design brief the appointed person shall consider:

Scope of the Work

Specification (Employer/Others)

Contract Drawings

Page 68
QA / QC Program World One Project

Site Investigation Report if Applicable

Function

Form of Structure and Geometry

Preferred Methods

Preferred Materials

Re-use of materials/scheme

Tolerance

Programme

Health, safety and environmental issues.

A standard solution may be the preferred method, in this case see section 7.8.

The design brief/Requirements will be prepared and will be submitted, together with
relevant drawings, sketches etc, to the TWC/ Engineering Manager to be passed on
to supplier/sub-contractor appointed to carry out the design or nominated designer or
Design checkers (see 7.3.3 and 7.51)

The information supplied in the design brief will include a description of the
preferred method(s) to be employed and sketches if complex schemes are required
by the site teams.

The Design Brief will be submitted to the TWC/ Engineering Manager and passed on
to the supplier/subcontractor, as appropriate, a minimum of two weeks prior to the
earliest date recorded on the front page the design brief. This period may require to
be increased for complex schemes.

Design and Checking

Page 69
QA / QC Program World One Project

The Engineering Manager will appoint the Designers & checkers to carryout designs
and third party checks on each temporary works elements. Every third party design
check will be approved by the Resident consulting Engineer.

When the design is carried out by the Designer will consider, amongst others, the:

Design brief

Temporary Works erection/construction tolerances

Loadings

Design Life

Design codes/British Standards

Other Publications/Design Principles

Statutory Requirements

Ground Conditions

Environmental Effects

Risk assessment/Method statement of the scheme identifying the major features to


be considered and the means of minimizing risks/hazards will be identified and
documented. Any residual risks will be identified and Communicated to the site
team.

The Designer will prepare calculations based upon the relevant British Standards,
Codes

of Practice and recognized principles. Sufficient drawings and sketches together with

outline method statements will be prepared to allow the Temporary Works to be

constructed, inspected, maintained and dismantled in a safe manner.

Page 70
QA / QC Program World One Project

Where the design has been prepared on site or by a third party or it is a prerequisite
of the design brief, the TWC/ Engineering Manager will be informed when the
design is completed in order that arrangements may be made by him for checking
and approval prior to implementation of the design. During the checking of designs
the checker will consider the ground, environmental effects, loading, overall stability
and design in both concept and detail

The checker will only refer to the designers calculations when in disagreement with
the elements of the prepared scheme. Any disagreement must be resolved between
the designer and checker before the issue of a check certificate/Report.

During the design phase, consideration will be given to checking the


erection/construction of the Temporary Works and hold points will be identified to
show when the scheme should be inspected by the TWC/TWS and/or the designer to
ensure Temporary Works are erected and maintained in accordance with the
drawings.

Implementation

Permit to Load

The TWS will identify, to the foreman or similar site supervisor, the specific hold
points noted by the designer and any others he considers necessary to allow for the
inspection and confirm that the temporary works are erected in accordance with the
approved scheme. The TWC/TWS will issue a permit to load, upon completion of
the

The permit to load will confirm that the Temporary Works have been erected in
accordance with the relevant drawings, sketches, method statements etc.

The temporary works shall be inspected by the TWC/TWS, and a new permit to load
issued, before any new loading condition is instigated.

Permit to strike

Page 71
QA / QC Program World One Project

Crushing of cubes to start from third day of casting

When 100% of the cubes crushed achieve 75% of the required 28 day compressive
strength, request to strike (RTS) the false work will be initiated by the Project
manager.

Compressive test values and approved layout of back propping shall be attached
along with the RTS. Completed RTS should be submitted to LODAH group for
review and approval.

Upon receiving the approval for RTS from LODHA group the contractor Project
Manager will issue instruction to strike the false work in coordination with the
TWC/TWS.

Documentation

To ensure the Procedure is implemented, a file of all correspondence and


certificates/Reports in connection with Temporary Works will be maintained by the
TWC.

Standard solution

The code of practice for falsework (BS 5975) permits the use of standard solutions.
A range of standard solutions is provided in section 8 of this code of practice.

In addition BS 5975 states:-

A standard solution involves the selection of a suitable combination of support


components for which the basic design work has already been carried out and
presented in tabular or other easily assimilated form, and for which no further
structural calculations are necessary.

Suppliers may also produce standard solutions to suit their products. These
standard

Page 72
QA / QC Program World One Project

solutions should be produced in accordance with the recommendations in BS 5975


and should be accompanied by information covering layout, loading, limitations and
tolerances together with information for safe erection and dismantling.

When selecting a standard solution those responsible should ensure they understand
and take account of the limitations of these designs so that they are only used in
appropriate circumstances.

Where a standard solution is employed no further design, checking or certification


is required. The standard solution should be clearly described in the method
statement.

Attachment A - Temporary Works Co-ordinator (TWC) - Responsibilities

The TWC will:

Be responsible to the Senior Site Representative with functional responsibility to the

General Manager - Construction.

2. Be aware of the Temporary Works Procedure and will co-ordinate the brief,
design and checking functions, inspection and certification of the safe construction,
maintenance, use
and dismantling of the Temporary Works on site. In the absence of the TWS be
responsible for checking and certification, in stages where applicable or stated by the
designer, of the safe construction, maintenance, use and dismantling of the
Temporary Works on site

3. When requested by the Senior Site Representative determine the requirement for
Temporary Works Schemes and, as appropriate, prepare a programme for design,
approval, materials, plant and work on site.

4. Liaise with the Engineering manager, the Senior Site Representative and the site
team to ensure that the design is submitted for approval (where required by the
contract) and is reviewed by the designer if the circumstances change.
Page 73
QA / QC Program World One Project

5. Ensure that the Temporary works scheme are prepared by subcontractors/supplier


and checked by the nominated Checkers in reasonable time.

6. Liaise with the, Designer, Senior Site Representative, other site staff and
subcontractors/ suppliers to ensure that the scheme is constructed in accordance with
the design and on programme.

7. Liaise with the Designer to ensure any modifications made to the design in the
course of erections are approved before proceeding.

8. Ensure that the designer and checker are informed of any variations to the
conditions originally envisaged and confirmation/amendment is received before
proceeding, eg ground, water, environmental or use.

9. Maintain a Temporary Works file on site, and ensure that it is available for
inspection by the Senior Site Representative and Engineering Manager.

10. *Issue, only when satisfied that it is safe to do so, a Temporary Works Permit to
Load/strike, indicating the date of inspection and the conditions certified i.e.
loading/striking may commence, excavation may proceed (specify limits if required).

11. *Provide copies of the Permit to Load/Strike to the relevant personnel e.g.
Section Foreman, who will sign to acknowledge receipt, the signed copy is to be kept
with the Temporary Works file.*These responsibilities may also be carried out by
the Temporary Works Supervisor.

If doubt exists refer to the Project Director or his nominee for further advice.

Attachment B - Temporary Works Supervisor (TWS) - Responsibilities

The TWS will:

Be responsible to the Senior Site Representative or his nominee with functional


responsibilities to the TWC/Engineering Manager.

Page 74
QA / QC Program World One Project

Be aware of the Temporary Works Procedure and will be responsible for checking
and certification, in stages where applicable or stated by the designer, of the safe
construction, maintenance, use and dismantling of the Temporary Works on site.

Liaise with TWC and/or Designer to ensure any modifications made in the course of
erection are approved before proceeding.

Ensure that the designer and checker are informed of any variations to the
conditions originally envisaged and confirmation/amendment is received before
proceeding e.g. ground, water, environmental or use.

Issue, only when satisfied that it is safe to do so, a Temporary Works Permit to
Load/strike, indicating the date of inspection and the conditions certified i.e. loading
may commence, dismantling may proceed (specify limits if required).

Provide copies of and inspection certificates/Reports and the Permit to Load to the
TWC and other relevant personnel e.g. Section Foreman, who will sign to
acknowledge receipt. A signed copy will be retained in the Temporary Works file.

If doubt exists refer to the Project Director or his nominee for further advice.

Page 75
QA / QC Program World One Project

Annexure III

List of Authorised Signatories

Page 76
QA / QC Program World One Project

List of Authorised Signatories

Sl.No Name Designation Sample Signature

1 Mahesh Bhudia Project Director

2 Deepak.A.Suvarna General Manager

3 Manish Thakur General Manager (MEP)

4 Russil Kumar Sr.General Manager (Safety)

5 Girish Mithra.V.S Sr.QA/QC Manager

Page 77
QA / QC Program World One Project

Annexure IV

QA/QC Report Forms

Page 78
QA / QC Program World One Project

Page 79
QA / QC Program World One Project

Page 80
QA / QC Program World One Project

Page 81
QA / QC Program World One Project

Page 82
QA / QC Program World One Project

Page 83
QA / QC Program World One Project

Page 84
QA / QC Program World One Project

Page 85
QA / QC Program World One Project

Page 86
QA / QC Program World One Project

Page 87
QA / QC Program World One Project

Page 88
QA / QC Program World One Project

Page 89
QA / QC Program World One Project

Page 90
QA / QC Program World One Project

Page 91
QA / QC Program World One Project

Page 92
QA / QC Program World One Project

Page 93
QA / QC Program World One Project

Page 94
QA / QC Program World One Project

Page 95
QA / QC Program World One Project

Page 96
QA / QC Program World One Project

Page 97
QA / QC Program World One Project

Page 98
QA / QC Program World One Project

Page 99
QA / QC Program World One Project

Page 100
QA / QC Program World One Project

Annexure V

List of Major Suppliers and


Contractors

Page 101
QA / QC Program World One Project

List of Major Contractors and Suppliers

List of Major Suppliers/Sub-Contractors may include but not limited to

Sl.No Scope of Supply / Service Major Suppliers / Subcontractors

1 Civil Works Arabian Construction


Company,Simplex JV
2 Form Work TBA

3 Water proofing works TBA

4 Ready Mix Concrete LAFARGE Ready Mix

5 Reinforcement TBA

6 MEP works TBA

7 Lifts TBA

8 Aluminum Glazing AND Faade TBA

9 Suspended Ceilings TBA

10 Steel Doors TBA

11 Wall finishes - Painting & Decor TBA

12 Flooring works TBA

13 Carpentry works TBA

14 Non-structural Metal works TBA

15 Scaffolding works TBA

16 BMU System TBA

17 Transformers TBA

Page 102
QA / QC Program World One Project

Annexure VI

Project Quality Objectivies

Page 103
QA / QC Program World One Project

Page 104

You might also like