Construction Quality Control And Assurance Procedure.docx

INSPECTION METHODOLOGY

I. II. III.

Review of Relative Documents Review of Quality Procedures Material Receiving (including Specifications and its documents) IV. Installations V. Testing and Sampling VI. Final Inspection VII. Pre-commissioning and commissioning VIII. Final Startup (MEPF only) IX. Final Handover

CONSTRUCTION QUALITY CONTROL INSPECTION PROCEDURE

FOREWORD

A. Earthworks

a. Scope This article provides guidelines for quality inspection limited for earthworks including leveling, grading, soil classification and soil testing. b. Intent and exclusion The intent of this article is to describe intrusive or non-intrusive techniques and equipments used for earthwork inspections. Engineering project consultant are responsible for suitable inspection techniques and/or combination techniques to address their specific need taking into consideration inspection effectiveness, timeline and cost. Selection of suitable technique(s) for specific applications is excluded from the scope of this document. c. Definition 

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Land surveying is the technique, profession, and science of determining the terrestrial or three-dimensional positions of points and the distances and angles between them. Field Density Test (FDT) is the process of determination of field density of cohesion less soil is not possible by core cutter method, because it is not possible to obtain a core sample. In such situation, the sand replacement method is employed to determine the unit weight. Boring Test is a tests performed by a geotechnical engineer by drilling holes into the soil in order to determine some or all of the following:(1) ability of the soil to support structures on the surface with or without additional assistance from footings, piers, and other aids; (2)

permeability of the soil to determine whether it will percolate sufficiently for an on-site septic system; (3) discover and monitor leakage from underground storage tanks or the presence of other contaminants. d. References    

Construction drawings and Plans Construction manuals and specifications Equipment manuals Testing Manuals and procedure

e. Overview of available types of surveys or survey methods and soil testing equipments and procedures used in construction i. Types of surveys 

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Location survey. This type of land survey is similar to a boundary survey but with additional information on the location of interior improvements. It is commonly used to fulfill the requirements of a loan application or zoning permits. Construction survey. This land survey is used to stake out structures, such as roads, walls, buildings and utilities. It involves slope staking, horizontal and vertical grading as well as an As-Built survey. Site planning survey. This type of survey is a combination of a boundary and a topographic survey. It is commonly used to design house lots, commercial & industrial sites, streets and highways, subdivisions, stores and playgrounds. Levelling is a branch of surveying, the object of which is to establish or verify or measure the height of specified points relative to a datum. Topographic survey is required to check possible highest and lowest elevation and grading on the specified lot. A topographic survey data should be included on the given plans from the designer or else a surveying engineer from the contractor can commence and gather data required.

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Responsibilities i. QCE inspector is responsible for:  Familiarization of all relevant standards, survey equipments and procedures and/or methodology.

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Checking of equipments used prior to commencement of survey or testing works.  Evaluation and analyzing survey results.  Comparison of survey result.  Testing and/or checking of test results from a third party geotechnical surveying company.  Creation and submittion of reports. ii. Survey and test equipments shall:  Be test by QCE prior to proceed.  Usable and in good condition.

g. Others For on site inspection, contractor must submit Inspection Work Request form one day prior to inspection day. For staking outs on columns, walls, equipment locations and etc. This will be verified by consulting engineers together with QCE for final.

FLOW CHART FOR SOIL TESTING PROCEDURE (FDT) AREA FOR TESTING

FILL

UNDISTURBED

CUT

PERFORM FDT

Yes

Pass as per designer’s required soil density percentage / 95%

No

Perform soil compaction

Proceed on Next scope of work.

No Perform FDT

Yes Pass on test?

Note: Use Inspection Work Request form-0001 for on site inspection.

B. Reinforcements Checking of hooks and bends should be in accordance with ACI(A100)/ACI-380 standards. a. Testing and commissioning i. Gathering of samples for rebars with differences in diameter should be at least 2 sets at 50 tons per batch given that the miller of the materials is the same. ii. Contractor is allowed to look for a third party material testing center and should be require to have a copy of permits and licenses including machine calibration certificate and subject for checking by QCE. Otherwise assigned company QCE may conduct a series of given that a consulting engineer is present.

Tensile Testing Procedure (For Reinforcement Bars)

b. On Site Inspection For quality inspection on rebards installed on site create a checklist to check the correct number of rebards(includes number of main bars, stirrups, lateral ties, bends, hooks, bar lengths and drilled bars) and the sufficiency of tie wires being used.

C. Concrete Before the construction begins the contractor will request certain trials of concrete mix to be used for testing to enable you to check the strength, workability, density and other properties of concrete mixes. Trial mixes are often undertaken when new materials or admixtures are to be used. Trials are also undertaken when setting up batch data. Trial mixes can help you maximize all the materials in the mix and is important for mix optimization. For concrete pouring procedure. Use Concrete Pouring Request form to check specifications and quality of the concrete being delivered to be perform by consulting engineer or inspector.

a. Testing  Collect 2 sets of samples to be used for testing. Refer to structural manual for the number and kind of samples to be collected as per designers requirement.  Contractor is allowed to look for a third party material testing center and should be require to have a copy of permits and licenses including machine calibration certificate and is subject for checking by QCE.  Test Procedure for Concrete o Concrete Cylinder Compressive test

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Flexural / Bending test

Procedure of Flexural Test on Concrete  

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The test should be conducted on the specimen immediately after taken out of the curing condition so as to prevent surface drying which decline flexural strength. Place the specimen on the loading points. The hand finished surface of the specimen should not be in contact with loading points. This will ensure an acceptable contact between the specimen and loading points. Center the loading system in relation to the applied force. Bring the block applying force in contact with the specimen surface at the loading points. Applying loads between 2 to 6 percent of the computed ultimate load. Employing 0.10 mm and 0.38 mm leaf-type feeler gages, specify whether any space between the specimen and the load-applying or support blocks is greater or less than each of the gages over a length of 25 mm or more. Eliminate any gap greater than 0.10mm using leather shims (6.4mm thick and 25 to 50mm long) and it should extend the full width of the specimen. Capping or grinding should be considered to remove gaps in excess of 0.38mm. Load the specimen continuously without shock till the point of failure at a constant rate (Indian standard specified loading rate of 400 Kg/min for 150mm specimen and 180kg/min for 100mm specimen, stress increase rate 0.06+/-0.04N/mm2.s according to British standard). The loading rate as per ASTM standard can be computed based on the following equation:

Where: r: loading rate S: rate of increase of extreme fiber

b: average specimen width d: average specimen depth L: span length 

Finally, measure the cross section of the tested specimen at each end and at center to calculate average depth and height.

Computation of Modulus of Rupture The following expression is used for estimation of modulus of rupture:

Where: MR: modulus of rupture P: ultimate applied load indicated by testing machine L: span length b: average width of the specimen at the fracture d: average depth of the specimen at the fracture

D. Steel a. Review Plans/drawing , notes, specifications and manuals for familiarization and inspection. b. Fixed, semi fixed and rigid connections Read AWS D1.1:2015 General Inspection Provisions and refer to Research Council on Structural Connections (RCSC) for a good quality inspection practice. c. Test and inspection. For testing welded joints, there are 3 types of test that can be used 1. Dye Penetration test which is a widely applied and low-cost inspection method used to check surface-breaking defects in all non-porous materials. 2nd is Magnetic particle Testing and 3rd is Ultrasonic Velocity test, this test was proven efficient rather than the other types of test that have been used.

i. Dye Penetration test procedure

1) SCOPE: This procedure covers the liquid penetrant examination by solvent removable penetrant process using color contrast technique for detecting surface discontinuities of base metal & weldment required by the applicable code & PO specifications. 2) APPLICABLE CODES & STANDARDS: This procedure covers the requirements as per the latest edition of: a) ASME Sec V, Articles 1, 6 & 24. b) ASME sec VIII Div. I Appendix 8. 3) APPROVED PENETRANT MATERIALS: The dye, developer & cleaner (all of same make) used for DP test shall be of reputed brands like Magnaflux, P Met, Flawguide, Orion & NDT and shall be of spray type conforming to the specifications given in ASME sec V. Dye need not be spray type. It can be applied using paint brush. Penetrant material shall be as per Article 6 of Sec.V. Halogen content shall not be more than 1% by weight. 4) SURFACE PREPARATION: Surface & adjacent areas within 1" to be examined shall be dry & free of all dirt, grease, lint, scale, welding flux etc. that can obscure surface openings or otherwise interfere with the examination. Typical cleaning agents that may be used are detergents, organic solvents, descaling solutions & paint removers. 5) PRE CLEANING: The parts or areas of parts to be inspected shall be clean & dry before the penetrant is applied. Area under examination shall be thoroughly cleaned with the cleaner from the same group of penetrant materials. Cleaning shall be by spraying or brushing and wiping with a lint free cloth. Any traces of lint shall be removed. Drying shall be accomplished by exposure to ambient temperature & a drying time of min 30 seconds shall be provided.

6) TEMPERATURE LIMITS: The temperature of the penetrant materials & the surface of the part to be examined shall not be below 10°C or above 52°C throughout the examination period. Temperature may be measured with 50°C thermal chalk. 7) PENETRANT APPLICATION: Apply the penetrant to the weld face side to be examined. During dwell time (10 min.), if necessary, the penetrant may be reapplied in case the first coat gets dried up. If the surface to be examined is large enough to preclude completeexamination within 10 minutes of developer application, the examination shall be performed in increments. If the penetrant dwell time exceeds the max. of 10 mins., then, testing shall be repeated from pre cleaning stage. 8) APPLICATION OF DEVELOPER ON THE OTHER SIDE: Apply developer on the other side of the weld to check for any through and through defects. Interpretation & evaluation of the discontinuity indications shall be carried out after developer time of Annexure-III Page 2 of 2 min. 10 minutes & max. 60 minutes. A minimum light intensity of 100 ft candles (1000 lux) is required to ensure adequate sensitivity during examination & evaluation of indications. 9) REMOVAL OF EXCESS PENETRANT: After the required penetrant dwell time, excess penetrant on the face side shall be removed as far as possible by wiping with a dry, clean cloth (lint free) repeating the operation until most traces of penetrant have been removed. All traces of lint shall be removed. Flushing the surface with cleaner following the application of penetrant & prior to developing is prohibited. The part surface shall be allowed to dry by normal evaporation & a drying time of minimum 30 seconds shall be allowed prior to application of developer. 10) APPLICATION OF DEVELOPER ON THE WELD FACE SIDE: Application of developer on the face side to check surface defects shall be by spraying to assure complete coverage with a thin & even film. Developer shall be applied as soon as possible after removal of excess penetrant but within 10 minutes maximum. Interpretation & evaluation of the discontinuity indications shall be carried out after developer time of min. 10 minutes & max. 60 minutes. A minimum light intensity of 100 ft candles (1000 lux) is required to ensure adequate sensitivity during examination & evaluation of indications.

11) INTERPRETATION & EVALUATION OF INDICATIONS: a) Final interpretation shall be made within 10 to 60 minutes after the application of developer. b) Interpretation & evaluation of indications shall be as per ASME Sec VIII Div. I Appendix 8. c) Only indications with major dimensions greater than 1/16" (1.6mm) are to be considered as relevant. d) A linear indication is one having a length greater than three times the width. e) A round indication is one of circular or elliptical shape with the length equal to or less than three times the width. f) Any questionable or doubtful indications shall be re-examined to determine whether or not they are relevant. g) Any adjacent indication separated by less than the major dimension of the smaller shall be assessed as a single continuous indication. 12) ACCEPTANCE CRITERIA: The following acceptance standards shall apply unless specified otherwise: All surfaces to be examined shall be free from: a) Any relevant linear indications. b) Relevant round indications with dimensions > 3/16" (4.8mm). c) Four or more relevant round indications in a line separated by 1/16" (1.6mm). 13) POST EXAMINATION CLEANING: Post examination cleaning shall be carried out as soon as practical with a cloth soaked with cleaner. 14) REPORTING: Liquid Penetrant examination report shall be prepared and submit to purchaser for review. ii. Magnetic Particle Testing

d. Results Collect results given by a third party testing centers for inspection to check the for defected members. If a member is happen to be defective the QCE will ask for methodology regardless on the result from the engineering consultant.

E. Masonry Inspection commonly for masonry works: 

Refer to specifications and manuals released or given by the consulting architect.

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If no specs and manuals being provided we can check local code – National Building Code (NBCP) or either of International Building Code(IBT), Masonry Standards Joints Committee and Building Code Requirements and Specification for Masonry Structures (TMS402/ACI 530/ASCE 5 and TMS 602/ACI 530.1/ASCE 6) to be used for inspection. Prepare checklist for checking base of this standards. Checklist must contain ratio of cement, sand and water, shrinkage and details on cracks due to shrinkage and rise of temperature, thickness of finish and finishing dimensions.

F. Interior design  Inspection for interior design will be base on the client’s architect’s manuals and specifications.  Create checklist base on the noted standards.

G. Site developments

H. Electrical a. Site visual inspection b. Testing

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Mechanical a. Site visual inspection Inspection for mechanical works including Airducts, Refrigeration, pumps, generators, elevators and other motorized equipment can be inspected by MEPF-QCE. b. Start up and testing

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Plumbing a. Testing

K. Fire protection and fire suppression a. Testing

L. Finishes Materials for finishing touch will be subject to inspection prior to application to ensure that the used materials are applicable and/or is correct.  Review designer’s or client’s manual for construction and specification.  Review plans and drawing with seal for site implementation.  Review materials specs and on site comparison for checking.  Create checklist for initial and final inspection. M. MECHANICAL INSPECTION AND TESTING  Scope This article provides guidelines for inspection on the development of inspection program for mechanical equipments including ducts, insulations, testing and machine startups. 

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Refence a. Mechanical code of the Philippines b. Electrical code of the Philippines c. Fire code of the Philippines d. Pluming code of the Philippines e. Project drawings: i. i.e. E-001 ii. i.e. M-001 f. Project Manual and Specifications Responsibilities 3.1 The inspection unit supervisor shall be responsible for: 3.1.1 Assuring that an inspection programs for inspection for ducts, insulation,