QUALITY CONTROL PROCEDURE QA/QC DEPARTMENT Ref :- UPF/QAQC/
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Quality Control Procedure
1. Purpose and Scope
2.
1.1.
This procedure describes fully in details all inspection methods that that will will be carri carried ed out during during the pre-pr pre-produ oducti ction on stage stage and post-production post-production stage.
1.2.
The aim of this procedure is to provide details and description of practices involved in good workmanship as well as to ensure proper quality standards of inspections as per the PCI and all the existi existing ng intern internati ationa onall stand standard ards s of Precas Precastt and Prestr Prestress essed ed concre concrete te produc products ts witho without ut underm undermini ining ng our client client’s ’s Projec Projects ts specifications and standards.
1.3.
This procedure shall be applied to the In-coming Inspections, Tes Testi ting ng labo labora rato tory ry,, in proc proces ess s prod produc ucti tion on and and fina finall fini finish sh products.
Management 2.1.
3.
The QA/ QC Department is managed by QA/QC Manager whose main responsibility is to make sure, at the stage of production until delivery, is closely controlled by his engineers / inspectors and always insist good product to the management and up to client satisfaction. A contract review by the department sees to it that the contract quality assurance is followed. The QA/QC is directly responsible only to the management and shall not be subject to control by the production.
Structure, Function and Responsibilities 3.1.
The QA/QC Department has three (3) major separate divisions: 3.1.1.
Quality Assurance Responsible for monitoring of the Laboratory works and the Batching Plant operations.
3.1.1.1.
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Responsible for all the tests that are being carried out in the inbuilt laboratory and to follow-up all the tests that are being carried out by the independents laboratories for further evaluation and deeper analysis of the materials. Constantly updates the validity of all products and materials.
3.1.1.3.
3.1.1.4.
Ensures all the materials that are being used in the factory shall comply with the PCI standards, International standards such as ACI, ASTM, BS, and all other requirements specified by the individual clients. Responsible for the continuous development of the Company’s Quality Manual in preparation for the application of ISO certification.
3.1.1.5.
3.1.2.
Production Quality Control
3.1.2.1.
Responsible for monitoring and controlling the quality of the Precast and Prestressed products being produced inside the factory in terms of dimension and geometrical tolerances of the elements, embedded items used, proper handling and placing of concrete, and proper method or system used during the mould preparations.
3.1.2.2.
Works hand-in-hand with the production department to ensure that the production procedures are properly followed and executed. Coordinates with the clients’ Inspectors (if any) during inspection to establish and create a trustworthy environment among them selves to be able to secure clients’ immediate approval during the production process.
3.1.2.3.
3.1.3.
Stockyard Quality Control
3.1.3.1.
Responsible for the coordination, control and monitoring of all incoming elements from the
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QUALITY CONTROL PROCEDURE QA/QC DEPARTMENT Ref :- UPF/QAQC/
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production line and all outgoing elements in the stockyard to be delivered at site. 3.1.3.2.
4.
Responsible for monitoring the curing of each element, repairing of damaged elements and final cosmetic process of all the elements prior to delivery.
Documents and Reports 4.1.
The QA/QC Department is required to issue and maintain the following documents on a routinely or daily basis. 4.1.1.
Internal Memos
4.1.2.
Material Visual Inspection Forms
4.1.3.
Sieve Analysis
4.1.4.
Mix Design Calculation Sheet
4.1.5.
Laboratory Trial Mix
4.1.6.
Presentation of Mix Design
4.1.7.
Batching Plant Concrete Mixes
4.1.8.
Shop Drawings Transmittal Log
4.1.9.
Concrete Casting Report
4.1.10.
Quality Inspection Check List
4.1.11.
Release of Concrete Casting Form.
4.1.12.
Concrete Demoulding Release Strength
4.1.13.
Daily Production Report
4.1.14. Routine 4.1.15. Quality
Inspection Report
Observations Report
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QUALITY CONTROL PROCEDURE QA/QC DEPARTMENT Ref :- UPF/QAQC/ 4.1.16. Daily
Rejection Report
4.1.18. Stockyard
control Before Delivery on Site
The QA/QC Department is required to prepare and issue the following reports on a regular basis depending on the required frequency by the individual clients and the management.
4.2.1.
Material Inspection Request
4.2.2.
Submitted and Approved Sample Summary Report
4.2.3.
Mix Design Approval
4.2.4.
Cube Test Report for Precast Elements
4.2.5.
Cube Test Report for Hollow Core Elements
4.2.6.
Laboratory Core Test Report
4.2.7.
5.
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Curing Status
4.1.17. Monthly
4.2.
Rev. 03
Validity of Products
Operation Procedure 5.1.
Inspection of Materials 5.1.1.
Special attention is given to the selection of basic materials such as cement, aggregates, etc. and tests are conducted regularly, thus ensuring compliance with the relevant standards such as (ASTM, BS, JIS, DIN or any particular requirements of the client). When necessary, tests are conducted by and independent laboratory on special request by clients.
5.1.2.
Each delivery of basic materials is carefully checked visually in coordination with the store department and the supplier.
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5.1.3.
Special materials related to the production of precast or hollow core elements arriving at the factory shall be subject to Material Inspection Request to be initiated by the supplier.
5.1.4.
Incoming materials which are found rejected are returned back to supplier for replacement.
5.1.5.
All Materials are stored to avoid contamination and maintain cleanliness.
5.1.6.
The materials that are used in production are tested according to standards, after the approval of QA/QC Manager.
5.1.7. Yearly
Status of Approved Products is edited by QA/QC Manager using Validity of Product.
5.2.
Project Samples 5.2.1.
Once the contract is signed and awarded, a copy of contract letter and specification (when applicable) is send to QA/QC Department to prepare concrete mix design according to contract requirements.
5.2.2.
Based on these information documents, QA/QC Manager will calculate the mix designs to be used for the production of the pre-cast elements.
5.2.3.
According to the requirement of the signed contract, studies will be done by QA/QC Manager to determine the technical and physical needs as well as the finishing result to be achieved for the production of elements.
5.2.4.
Mix Design Calculation Sheet, Presentation of Mix Design & Sieves Analysis will be calculated.
5.2.5.
Laboratory Trial Mix form will be send to the concrete Lab for test only when applicable, if new product is to be elaborate or if required by client for known concrete.
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5.2.6.
Record of trial batch will be done by QC Lab Technician and results of strength from Cubes will be analysed by QA/QC Manager.
5.2.7.
All information about materials used for the new mix will be analyzed (cement, aggregates, water, admixture) and a full package will be send to the client representative for mix approval.
5.2.8.
Quality Assurance Engineer together with the Lab Technician will now then prepare the Finishing samples for client’s approval. new mix design will be part of the Batching Plant Concrete Mixes. This document, updated every month is dispatch to the production department for record and used.
5.2.9. This
5.2.10.
As soon as QA/QC department receive approval for the mix design from the client representative, one copy of the Presentation of Mix Design will be forward to the production department with “APPROVED” stamp on it.
5.2.11.
This document will define also the type of curing process to be applied after casting and shall be filed and logged in the laboratory department for reference.
5.2.12. Then 5.2.13.
5.3.
only the production can start.
As soon as QC department receives approval for the finished face from the client representative, one sample, duly signed will be forward to the production department for reference. Submitted & Approved Samples Summary will be completed by Lab Technician.
Control of Concrete Quality 5.3.1.
Once the production have started, all concrete used for precast elements and prestressed products shall be controlled according to the following procedures: 5.3.1.1.
Initial concrete cube testing shall be conducted during the first production period using the Cube Test
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Report Form for precast or hollow core elements as a Test Certificate for client’s approval.
5.3.2.
5.4.
5.3.1.2.
Frequencies of testing during the production period will depend on the agreed contract between the client and the precast manufacturer or shall be at least minimum one (1) set for different mixes daily. Final Records shall be logged on the Concrete Casting Report.
5.3.1.3.
Concrete Temperature, slump and all other related data are also to be recorded using the Concrete Casting Report.
5.3.1.4.
Sieve Analysis on each aggregates including sand using Sieve Analysis Form.
5.3.1.5.
Concrete Samples taken from the production area shall be subject for compression test on a regular basis using the Concrete Casting Report t.
5.3.1.6.
Concrete core samples are to be tested from the produced element for further analysis and testing, if required, using the Laboratory Core Test Report as per clients’ request.
5.3.1.7.
Concrete Demoulding Strength shall also be tested during the first full week of the production stage using the Concrete Demoulding Release Strength Form to determine the average demoulding time needed for establishing the production cycle. This test report is only for information purposes and should only be carried out in the full discretion of the QC Department or as per the request of the clients.
A regular routine inspection plan for concrete mixes shall be implemented through batching report and cube test results.
Control of Batching, Mixing and Transporting
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During the production operation QA/QC Department shall be responsible also for the control of Batching Plant, Mixing and Transport Equipments:
5.4.1.
Equipments shall be thoroughly checked before starting of production each day and each shift particularly when producing different types of white mixes.
5.4.1.1.
Aggregates of each type that are stockpiled on each bin separately shall be monitored and inspected regularly to prevent them from contamination.
5.4.1.2.
Separate Transportation for white mixes and grey mixes are to be ensured to prevent from product discoloration.
5.4.1.3.
5.5.
5.4.1.4.
Weighers such as cement, aggregates and water are calibrated annually by an independent laboratory.
5.4.1.5.
Information of the Mix Designs is to be kept and recorded for batching plant references.
Production Quality Control 5.5.1.
Production QC Engineers and Inspectors for the PCC Elements shall use the Quality Inspection Check List for inspecting each mould as per code of good practice and against the approved shop drawings before casting: Drawing number documents.
5.5.1.1.
5.5.1.2.
validity
according
to
design
Formwork condition (preparation, paint surface, mould face appearance clearness, cleanliness etc.) and dimensions as per approved shop drawings. Rebar distribution, cleanliness, concordance with approved drawing, geometrical condition and proper covering.
5.5.1.3.
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Embeds and openings located as per shop drawing (electrical boxes, lifting sockets, conduits, sleeves, plates, block outs, windows, doors etc.)
5.5.1.4.
Concrete mix as per approved mix, placement, vibration and finishing.
5.5.1.5.
5.5.1.6.
Curing at setting time before demoulding.
Control of demoulding strength on cubes, in collaboration with QC Lab Engineer before demoulding. Approval by QC Department is needed prior to demoulding procedures.
5.5.1.7.
Final checking before demoulding and transfer to stockyard.
5.5.1.8.
5.5.2.
Production QC Engineers and Inspectors for the Hollow Core shall use the Hollow Core Production Report for inspecting each Hollow core element production, before, during and after casting. 5.5.2.1.
Shop drawing and element mark.
5.5.2.2.
Applied pulling force, initial stress and final stress.
5.5.2.3.
Required elongation, actual and average.
5.5.2.4.
Release strength before cutting.
5.5.2.5.
Dimensional checking after casting.
5.5.2.6.
Element markings.
5.5.3.
All Production QC Engineers and Inspectors shall use Daily Production Report to follow element cast by type of contract, reference number, concrete required strength, casting time, demoulding time, and remaining element to be cast.
5.5.4.
Production QC Engineers and Inspectors also use the Release of Concrete for Hollow Core Panel Casting prior to start casting of the elements.
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5.5.5.
Production QC Engineers and Inspectors shall use Routine Inspection Report or Quality Observations Report for any question in the process of production and any kind of alternative to be provides. This document will be send to QA / QC Manager for analysis before action.
5.5.6.
Daily Production Reports are to be established and to be fully documented every day by Production QC Engineers.
5.5.7.
Production QC Engineers and Inspectors must refer to QA/QC Manager, using Internal Memos, Routine Inspection Report or Quality Observation Report for any changes in the process of production or any kind of alternatives provided.
Stockyard Quality Control 5.6.1.
Stockyard QC Engineers and Inspectors shall use Incoming Element Form from the production department as their reference to monitor all elements coming for the production area. The data to be reported are the Element Marks, Casting Dates and Contract number.
5.6.2.
Stockyard QC Engineers and Inspectors shall use Daily Curing Status to monitor all elements during curing time required (for water curing only). The data to be reported are the curing hours, Element Marks and Stockyard Location.
5.6.3.
Stockyard QC Engineers and Inspectors shall use Monthly Rejection Report to monitor all rejected element before delivery and for statistical rejection analysis.
5.6.4.
Stockyard QC Engineers and Inspectors shall use a copy of Delivery Request Form from the erection department to know about coming delivery, and Stockyard Control before Delivery on Site to get a full record of all elements before delivery when special requirement as per contract. Element dimensions, curing and repair status and finishing should be counter checked again prior for delivery.
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5.6.5.
Stockyard QC Engineers and Inspectors will sign and confirm the Delivery Note requested by the erection department, which attest the final checking before delivery. With this signature, the load is allowed to be transferred on site.
5.6.6.
Stockyard QC Engineers and Inspectors are in charge to advise and to monitor cosmetic repair to be carried out on precast element.
5.6.7.
Stockyard QC Engineers and Inspectors are in charge to monitor the final finishing works in accordance with the required finishing approved by the client.
5.6.8.
No single precast or Hollow Core element unit may be dispatch without receiving the full approval of the QC Engineer in charge of the stockyard area.
5.6.9.
Stockyard QC Engineers and Inspectors must refer to QA/QC Manager, using Internal Memos, Routine Inspection Report for any changes in the process of stocking and handling or any kind of alternatives provided.
Site Quality Control (to be arranged if required) 5.7.1.
QA/QC Manager will perform random inspection for sites where QC Engineer is not contractually required. Observations and comments will be forward to Construction manager and or Production Manager for immediate action.
5.7.2.
QC Site Engineer is in charge shall monitor all erection activities on site when required by contract and to confirm, using Internal Memos, Routine Inspection Report the concordance of erection with international standards such as ACI and PCI. The items that are to be carefully monitored are the Erection methods, Tolerances, Alignments, Grouting works and fixing.
5.7.3.
QC Site Engineer must refer to QA/QC Manager, using Internal Memos, Routine Inspection Report or Quality Observation Report for any changes in the process of erection or any kind of alternatives provided.
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Site Repair Engineer from Erection Department will carry out all cosmetic repairs, using Repair on Site Form before handing over the project to the client.
- END OF PROCEDURE -
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