Quality Plan
Quality Plan
This quality plan was developed to assist the quality team to perform quality inspection
of concrete works performed by Al-Shorouk Construction.
Organization:
Project Organization
E-JUST
Project Manager
Construction
Technical Manager Financial Manager Safety Manager
Manager
Purchasing
QC/QA Engineers
Engineers
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Quality policy
The Quality Policy is to deliver products and services to the Client in conformance with the Contract
requirements, on time, and free of defects. Al-Shorouk Construction have developed a Project Quality
Plan in accordance with the Client’s quality requirements for the Contract. The contents of the Project
Quality Plan are binding on all staff and all the subcontractors in carrying out their duties. The policy
aims to satisfy the following objectives:
Describing the inspection process and supporting documents, and to ensure that the control over
the tested material is in compliance with the project specification requirements, in order to
guarantee project owner satisfaction and approval.
Ensure concerned project staff acquisition of all necessary documents.
Defining the system of receipt and verification of material and its storage, handling and control, in
order to achieve best utilization of resources and minimize wastage.
Ensure the detection, control and correction of all non-conformances, and to correct the root causes
for non-conformances to prevent recurrence.
Get approval for all submittals.
Meeting the requirements of the Contract and the quality achievement criteria in it.
Forming an organization structure that is adapted to act proactively and smoothly whenever
possible.
Adopting a continuous improvement mentality that systematically captures and considers the
different experiences as management of non-conformities, internal audits, correction and
prevention measures and management review.
Continually aim to achieve a fruitful collaboration between the various parties in the project.
Ensure submittals, work inspections and Material Inspection approvals.
Follow written and documented procedures to ensure that the work instructions are clear, job
descriptions and responsibilities are well defined, and that all activities and actions are carried out
and in an auditable manner before commencement of any activity.
Ensure that the correct and updated documents and drawings are distributed to all involved parties.
Ensure that the most adequate, economical and safe construction methods are adopted.
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Roles and Responsibilities
Project Manager •Report to Business Unit Director on quality performance and issues
(Project Director/ Deputy Project Director)
•Establish and ensure implementation of the execution strategy, policies
and organizational structure required for on time, on budget, safe and to
specified requirements completion of the Project
•Lead all Project Departments and resources to achieve all Project
Objectives
•Select key staff and delegation of duties to principal staff members
•Set the agenda and schedule for principal meetings, convene and chair
meeting.
•Authorize principal Project documents.
•Orientation of key staff, their on-going supervision, development and
assessment
•Authorize purchase orders and work orders.
•Determine and approve sufficient resources (personnel, materials,
plant/equipment , etc.) to ensure adequate implementation of PQP and
Programmed achievement
Quality Manager / QC •Report to the Project Director and Quality Director
Manager: •Lead effectively a team of Senior and Quality Engineers to achieve
project specified inspection and testing requirements on-site and off-site
•Development, maintenance and monitoring of implementation of PQP
•Scheduling, conduct and reporting of audits of subcontractors and
suppliers as deemed necessary
•Lead continual improvement practices for the Project lifecycle by direct
involvement, supervision or support to achieve performance objectives
and targets
•Development, maintenance and monitoring of implementation of
PIP/ITP
•Expediting and review of sub-contractors' and suppliers' plans and
procedures
•Establishment, maintenance and monitoring of document control
system and overseeing the functioning of the process
•Establishment and implementation of system for compilation of quality
record files
•Management and development of quality control personnel
•Provision of awareness training to Project personnel concerning PQP,
PIP I ITP, Work instructions & Method Statements
•Training needs assessment and provision
•Determination of any adverse quality trends and taking requisite action,
in conjunction with others as appropriate, to add1·ess issues arising
•Overseeing material compliance testing
•Ensuring compliance with national and international standards and
legislation
•Ensuring tests and procedures are properly understood, carried out and
evaluated and that the product modifications are investigated as
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necessary
•Working with purchasing staff to establish quality requirements from
external suppliers
Quality •Report to the Quality Manager
Control •Being fully conversant with specified requirements and the PIP
Engineer •Scheduling inspections of works to match progress
•Ensuring the attainment of specified requirements
(Civil,MEP, •Raising NCR's for non-fulfilment of specified requirements in completed
Architectural, etc.): works
•Expediting corrective and preventive action proposal responses to NCR's
raised and their action upon acceptance
•Re-inspecting works to ensure corrective and preventive actions taken
are adequate
•Supports the Construction Team on consolidated punch-list team
activities and subsequent acceptance of systems up to mechanical
completion
•Review Quality Control related change orders related to Construction I
Commissioning activities
Materials Engineer: •Report to the Trade Manager
•Determine and administer policies and procedures relating to shipping
receiving and storage of a variety of equipment, supplies and materials
•Coordinates materials testing projects, including hands-on testing
•Prepare performance evaluation reports documenting test
methodologies, calculations and results
•Identify and quantify all equipment and materials to be procured
•Oversee material take-off and equipment specification activities within
the engineering group for accuracy and timelines
•Participate at development of standard designs and associated bills of
materials to facilitate an efficient and effective method of material take-
off
•Develop and maintain a "Recommended Spare Parts List" for the project
•Ensure that supplies, materials and equipment received from vendors I
Suppliers/manufactures are up to project standards.
Site engineer •Exercising full control over the workforce on site.
•Ensuring that work is executed in accordance with the contract
drawings and specifications, agreed procedures and method statements.
•Preparation of designated procedures.
•Monitoring all Sub-contractors work closely to ensure that the Quality
of the work is as per specification and is completed on time.
•Completing all necessary Q.A. documentation related to the work under
his direct control and co-ordinate daily site inspections.
Laboratory Technician •Is responsible for Assisting the Quality Control Engineer in the
performance of all tests on site.
•Make the required testing at the laboratory.
•The conduct of tests in accordance with the technical provisions of the
specifications
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Quality definitions
Term Definition
Objective EvidenceData supporting the existence of something, and may be obtained
through observation, measurement, test, or other means.
Procedure Specified way to carry out an activity or a process.
Process A set of interrelated or interacting activities which transforms inputs
into outputs.
Project A unique process consisting of a set of coordinated and controlled
activities with start and finish dates, undertaken to achieve an
objective conforming to specific requirements, including the
constraints of time, cost and resources.
Quality The totality of features and characteristics of a product or service
that bear on its ability to satisfy stated needs.
Quality Policy The overall quality intentions and direction of an organization
regarding quality, as formally expressed by senior management.
Quality Assurance All those planned and systematic actions necessary to provide
(QA) adequate confidence that a product or service will satisfy given
requirements for quality.
Quality Control The use of operational techniques and activities that sustain the
(QA) product or service quality to specified requirements.
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Comparison Between Quality Control Quality Assurance:
Focus on: QA aims to prevent defects with a focus on QC aims to identify defects in the
the process used to make the product. It is finished product. Quality control,
a proactive quality process. therefore, is a reactive process.
Statistical Statistical Tools & Techniques can be applied When statistical tools & techniques
in both QA & QC. When they are applied to are applied to finished products
Techniques:
processes (process inputs & operational (process outputs), they are called
parameters), they are called Statistical as Statistical Quality Control (SQC) &
Process Control (SPC); & it becomes the part comes under QC.
of QA.
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QA / QC Guidelines:
The QA/QC team will meet with all parties involved in any deficiencies to determine a
solution to the problem. The solution will then be recorded and implemented in
accordance with the contract documents. Once the deficiency has been rectified, the
quality control inspector will re-inspect the original deficiency in regard to the agreed
solution.
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Quality Assurance / Quality control procedures:
1- QA/QC team shall provide general review of the construction of the structural
components of the work to meet the requirements of the technical specifications
and drawings issued by project design consultant for implementation that
should address:
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c- Inspect material related to structural works and provide to contractor, written
reports of approval and the actions that must be taken if material is not
approved; this report to be issued on day of inspection.
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A. Testing:
The QC team will take random samples and test them for conformance with the
contract documents. These results will be distributed to all parties. The Quality
Control Coordinator will review all test results and follow up as appropriate.
B. Samples:
Approved samples of materials to be incorporated into the job will be
maintained in the site office for use in comparing to installed material. Site mock-
ups, as required, will be maintained during construction at designated location
on site.
All materials and workmanship throughout the works shall comply, at minimum with
requirements given in this specification.
All materials used throughout the works shall be of best quality and conform in
all aspects with the appropriate Egyptian standard specification.
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Excavation shall be carried out in a safe manner to suitable lengths, widths,
depths and profiles required for the construction of the works shown on the
drawings.
All materials obtained from the excavation (surplus or not approved by project
manager) shall be removed to spoil as instructed.
C- Concrete
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Concrete Mixing
Concrete Placing
Concreting of any portion or section of the work shall be carried out in one continuous
operation and no interruption of concreting work will be allowed without the approval
of the project manger
Concrete shall be placed in horizontal layers and vibrated until it completely fills the
formwork, no external vibration should be used.
Concrete shall not be placed from greater height than 1.2 m to avoid segregation;
engineer’s approval will be required for greater heights. Equipment for mixing and
transporting concrete will be subject to project manager approval and periodical
inspection
Freshly deposited concrete shall be protected from the sun, wind and rain until it
has thoroughly set. The means adapted for such protection shall be to the project
manager approval.
Concrete shall be kept wet and cured until final setting is achieved
Contractor to submit detailed plan for concrete protection and curing including
hot weather precautions recommendations for project manger approval
Classes of concrete
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The classes of concrete shall comply with the requirements specified in the
Egyptian standard Specifications and as follows:
During the progress of work in the site and upon request of the engineer Al-
Shorouk Construction shall prepare and submit at any time further groups of
two by three test cubes (150 mm side length) in accordance with the Egyptian
standard specifications. The cubes to be tested after 7 and 28 days (depending on
the standards that will be chosen)
The specimen must be made in steel or cast iron moulds and kept in moist
ambient air at least 90% relative humidity for 24 hours.
Test cubes will be taken in a minimum rate of one set of 6 cubes every 50 m³ of
concrete if the casted quantity is more than 50 m³. If the casted quantity is less
than 50 m³ per one day, a minimum set of 6 cubes will be taken. Generally test
cubes will be taken as directed by the engineer’s representative.
In the event of failure of test cubes the project manager may order the drilling
and testing of cylinders from the mass or the carrying out to load test or the other
non-destructive tests on concrete structures.
In the event that the concrete does not comply with the required quality Al-
Shorouk Construction shall remove the concrete and replace it.
All concrete placement and testing must be witnessed by the project manager or his
representative. 24 hours placement and testing notice must be provided.
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Formwork
All exposed concrete surfaces including the inner surfaces of tunnels shall be of
fair face concrete by using plywood or approved alternative, up to the
satisfaction of the project manager, all edges should be trimmed and/or
chamfered.
All concrete work shall be impervious in order to prevent moisture loss from the
formed surface of concrete. Form materials shall be one of the following:
D- Steel Reinforcement
Steel characteristics
Steel reinforcement comply with the requirements of Egyptian standard 262 (steel bars
for reinforced concrete) can be used provided that its characteristics shall be considered
in design.
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Steel 24/37 (normal 240 370 20%
mild steel)
a- Tensile test
b- Cold bend test
c- Chemical analysis test
Reinforcing bars shall be placed in accordance with the drawings. The bars must
be connected with each other and with the stirrups with double iron wire and
must be supported by special bars and specially manufactured concrete spacers
so as to ensure that they do not move during the concrete operations. Concreting
must be done after the reinforcement work has been approved by the project
manager.
Minimum splicing will be allowed. Welding shall only be done with the explicit
approval of the project manager.
E- Pre-stressed concrete
Materials
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All materials for pre-stressed concrete shall comply with the applicable
requirements
load shall be 5%
statement detailing the materials, systems and quality inspection for pre-
stressing activity.
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Inspection and Test plan(ITP):
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4 Formwork and Dimension QC Civil 1-To make INSPECTION
spacers tightness, inspector formwork joint RECORD FOR
location, waterproof, CONCRETE WORKS
orientation foam tape tube
and to be used.
Cleanness. 2-Form work will
be adequately
propped, braced
and tied in
position to
ensure that it
retains its shape
and position
before, during
and after
concreting.
3-Formwork will
remain in place
until the
concrete has
hardened
sufficiently to
resist damages
from the
removal
operation which
in this case in a
minimum 24
hours after
placing of
concrete.
4-Chamfer
25X25 mm shall
be placed in
forms to bevel
all edges except
bottom edges of
foundation.
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5 Steel reinforcement Wire mesh QC Civil I-Fabrication & INSPECTION
wire mesh type, cover, lap inspector Deformation of RECORD FOR
distance and steel will be CONCRETE WORKS
fixation done at
Reinforcement
fabrication shop
at site or at
external
factories
approved by QP.
2- Assembled
reinforcement
will be erected
manually using
crane /suitable
lifting
equipment (if
necessary)
3-The spacer
blocks will be
prepared near
Reinforcement
yard from the
same mix the
surrounding
concrete.
4-Clear cover to
reinforcement
shall be
provided as per
standard of QP
spec and
SP3392-32-18-
17- 0004
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6 Inspection prior to Formwork, QC Civil approved for 1- INSPECTION
concrete pouring reinforcement inspector construction RECORD FOR
and spacers work procedure CONCRETE
final check 2- POST-POUR
INSPECTION
RECORD FORM
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exceed 35
degree
centigrade
8 Concrete test Tests for QC Civil As per 1.COMPRESSION
concrete inspector requirements of TEST ON CONCRETE
project specs CUBES
2.CONCRETE
POURING REPORT
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Checklist of Quality Plan
Foundation Checklist
Columns Checklist
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Concrete Walls Checklist
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Engineered Masonry Checklist
Review with
contractor the test
required for
engineered
masonry
Review reports
prepared if
engineered
masonry is used
Review typical
bearing details
and anchorage
Review with
contractor
Supply of
masonry units to
specified
strength, mortar
and grout
requirements
Check
reinforcement
size, spacing and
placement.
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Slab on grade Checklist
Review with
contractor the
specified floor
finish tolerance
Check slab
thickness and
location of
bulkheads for
construction joints
Review the
proposed curing
methods and that
compatibility with
subsequent finishes
has been
considered
Check insets,
embedded items,
block-outs, sleeves,
etc.
Review inspection
reports of concrete
supplied
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Concrete Works
Special aggregate
grading in columns,
walls or slabs
Concrete testing on
high strength
concrete
Verify that proposed
mixes have been
submitted to
consultant and
accepted
Specified tolerance
Requirements for
review of formwork
constructed
Curing procedures
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Checklist for Excavation
Survey works
(axes, levels…etc)
Review
geotechnical
reports
Review
requirements for
movements of
shoring
Formwork Checklist
Review reports of
site of Formwork
and shoring
Check inserts,
embedded items ,
block-outs, sleeves
Before concrete is
placed check that
Formwork is clean
of debris and
other materials
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Checklist for Steel Structures
Review reports
submitted by
structural steel
contractor
Check beams
dimensions,
rebar , size,
quantity cover of
beam
Review inspection
reports of concrete
supplied
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Checklist for Flat Slab
Check slab
thickness; rebar,
size, spacing,
cover, chairing
slab pouring areas
Review inspection
reports of concrete
supplied
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