Guideline For Inspection and Test Plans
Guideline For Inspection and Test Plans
1
Hadi International Trading & Contracting Co. Effective: 17.03.17
1.2 Glossary
Hold Point - A ‘hold’ point defines a point beyond which work may not proceed without the
authorisation of a designated service provider or authority.
Witness Point - A ‘witness’ point provides a party (such as the customer, service provider and a
regulatory authority) with the opportunity to witness the inspection or test or
aspect of the work, at their discretion.
Surveillance - Intermittent monitoring of any stage of the work in progress (whether by the
service provider or customer).
Self inspection - Where the service provider performing the work verifies the quality progressively
- often with the aid of checklists.
Work area - A discrete section of the whole work, usually defined by location, where any
trade work or activity would be completed before it moves onto another area.
Examples include a wall, a room, a building, a length of pipeline between
manholes and the like. Also referred to as lots.
1.4 Overview
The following steps are involved in documenting Inspection and Test Plans for a construction
contract: -
Step 1 Read the contract documents (including the technical specifications) and prepare a
list of any discrepancies, ambiguities, missing information and standards of materials
and/or workmanship that are considered inappropriate.
Step 2 Contact the customer and resolve the issues listed as a result of Step 1.
Step 3 Examine the scope of work and divide it into separate areas requiring an Inspection
and Test Plan (where not already prescribed in the contract documents). As a
general guide it is normally most convenient to document a separate Inspection and
Test Plan for each trade or work area/section.
Step 4 Note the Hold and Witness Points required by the customer (including as listed in the
contract documents).
Step 5 Review the contract documents again and note the requirements that have the most
impact on the quality of the finished work. For each, ask the question “What will be
the consequences if it is not made sure this is right?” Be certain to include any
references to tests, submitting information to the customer, obtaining approvals and
Hold and Witness Points (see 1.6.9 for further information).
Step 6 Determine from Step 5 which items or aspects of each inspection will need to be
recorded on checklists and prepare these.
Step 7 Discuss the checklists with those directly involved with the work and obtain their input.
This input should particularly be directed at identifying those issues that have caused
problems (and involved extra costs) in the past, and therefore warrant checking at the
earliest opportunity to avoid unnecessary and costly rectification.
Step 8 Prepare each Inspection and Test Plan to reflect the requirements of the contract
documents. Reference the ITP in the Quality Management Plan and cross-reference
to the other related ITPs.
Step 9 Issue each Inspection and Test Plan and/or associated certification to the customer
for consideration within a reasonable period prior to commencing the work described
in the Plan and adjust them to suit any comment received (or act as otherwise
required in the contract documents).
Step 10 Decide how best to divide the whole of the work into work areas for control purposes
and indicate these locations either on a schedule (with reference to grids and levels)
or by marking up drawings.
Step 11 Prepare and issue checklists for each work area and identify them according to
location.
Step 12 Train those directly involved with each of the ITP in their use. Formalise a procedure
for the notification of Witness and Hold Points to the appropriate person(s).
Step 13 Carry out inspections and tests in accordance with the Inspection and Test Plans,
provide notices to the customer and/or regulatory authorities for Hold or Witness
Points, as designated or applicable, and record the results on checklists.
1.6.1 General
1.6.2 to 1.6.9 inclusive describe what needs to be considered for each component of an
Inspection and Test Plan. They explain the components and how to select the relevant
information required for each.
The characteristics to be verified will frequently determine the stage at which the inspection or
test must take place if the potential for subsequent nonconformities is to be avoided. This further
work might also cover up or deny access for the purposes of verifying certain characteristics.
Some characteristics can only be considered after one particular operation and before another,
such as the inspection of steel reinforcement after installation but prior to the pouring of concrete.
1.6.4 Stage/frequency
The inspection/test stage/frequency will often be determined by the requirements of the contract
documents or by the type of inspection and/or test and the characteristics under consideration,
as outlined above. In the latter case however, there is the potential for a considerable range in
what constitutes the most appropriate frequency and sampling process. It is suggested that a
representative sampling of the work to suit the risks involved be used as a guide initially.
Thereafter, frequencies would be increased and processes reviewed for ‘problem’ work activities
and decreased where consistent conformity was evidenced.
1.6.5 Records
Records are essential to quality management because they provide the documented evidence
necessary to verify that a product/service is in accordance with the contract requirements.
The records would be in various forms, and would include the checklists, test certificates,
certificates of compliance/conformity, survey data, written approvals and the like. Inspection and
Test Plans would help define the records required.
1.6.6 Specification/standard
The standards against which conformity is measured can take various forms. The most common
source is usually the contract technical specification. Other standards would often be referenced
in this document, and may include any of the following: -
- Contract documents/specification generally
- Contract drawings
- Approved workshop drawings and/or calculations
- Approved technical details/procedures
- Approved samples and/or prototypes
- Regulatory requirements
- Australian Standards
- International Standards
- Standard specifications
- Manufacturers’ recommendations
A typical test procedure using statistical techniques might, for example, cover:
- reference to work areas/lots or batches
- frequency of sampling
- method of taking samples
- method of conducting a test (including conditions)
- qualifications of test personnel and equipment calibration/condition/specification
- method of documenting results
In some cases it may be possible to satisfy the requirements simply by referencing the
requirements of Australian Standards and the like.
1.6.10 Checklists
As noted in 1.6.2, with some work, the logical stage to carry out an inspection or test is often
after a number of separate activities, but prior to a major one that will cover up previous work.
It is often useful to complete checklists at such stages and with each inspection and test - where
they will, in effect, summarise the procedures that have, and should have, taken place up to the
particular point in the work process.
Checklists are useful reminders to the person doing the work of all the matters that are to be
addressed. They are used to confirm all the matters have been attended to. They are also
reminders to the person inspecting the work of all the matters that should be checked.
A checklist also gives an opportunity to record any special or unusual conditions under the
contract, and draw these to the attention of the people doing the work. For example, special
precautions for protecting existing work, notifications to the public, and other matters that might
not normally be required for the particular trade or activity, may be included.
The fact that checklists exist, and that their use and content have been verified, would give a
customer confidence that the person doing the work is aware of all the important steps, attributes
and matters to be addressed, and the standards that should be complied with, and that
conformity is being verified.
5 MANAGEMENT RESPONSIBILITY
Does the service provider identify and include all customer requirements in ITPs (Clause 5.2)?
Is the contract quality representative nominated in the ITPs? (Clause 5.5.3)
Do the ITPs nominate the person responsible on site for all key and related construction
activities? (Clause 5.5.3)
6 RESOURCE MANAGEMENT
Do the ITPs identify the resources proposed to carry out inspections and tests? (clause 6.1)
Do the ITPs include the minimum required qualifications and experience of the people that are to
carry out inspections and tests? (Clause 6.2)
Do the ITPs identify the required equipment, facilities and supporting services? (Clause 6.3)
Do the ITPs identify each critical working environment? (Clause 6.4)
7 PRODUCT REALISATION
Are the ITPs updated to reflect changes to customer requirements? (Clause 7.2)
Do the ITPs identify inspections and tests to verify/validate design? (Clause 7.3)
Do the ITPs identify the inspections and tests required to ensure that the products/services meet
the requirements? (Clause 7.4)
Do the ITPs reflect the control of conditions required for inspection and testing? (Clause 7.5)
Do the ITPs identify whether the monitoring and measuring equipment are calibrated and to
specification? (Clause 7.6)
Do the ITPs include the methods for indicating when nonconformity control is initiated and for
closing out work areas?
Have inspection and test forms been developed and implemented for recording inspection and
testing for each activity? (each stage in a process may be on separate but linked forms)
Receiving inspection
Do the ITPs define responsibility for verifying conformity of the supplied product to requirements
before using it in the constructed works?
Do the ITPs adequately address the inspection and testing requirements for the supplied product
before it is used in the constructed works?
In-process inspection
Do the ITPs define responsibility and provide for in-process inspection and testing?
Do the ITPs adequately address the inspection and testing requirements for all the
products/services during construction of the works?
Final Inspection and Testing
Do the ITPs define responsibility and provide for final (or acceptance) inspection and testing?
Does the service provider have a method and define responsibility in the ITPs for final review of
all inspection/test results to confirm that all inspections and tests have been carried out to verify
completely conformity to product requirements for each work area?
SAMPLE FORMS
Inspection and Test Plan
Customer: INSPECTION AND TEST PLAN for: (Insert work activity)
Contract Number: Work area: (Insert work area)
Contract/Project Name:
Ref Operation or stage of work Stage/ Records Requireme Acceptance Inspection/ Inspection *what/who
Description Characteristics frequenc nt/ criteria test Employee Service Customer
y standard/ procedure provider
specificatio
n
*W = Witness Point; H = Hold Point; H(A) = Inspection/Test by Authority; U(C) = Inspection/Test by Consultant; S = Surveillance or monitoring;
X = Self inspection by performer of work.
Checklist
INSPECTION AND TEST PLAN CHECKLIST for:
(To be completed by the person(s) directly responsible for the work)
Contract Number: Work area: Checklist Number:
Contract/Project Name:
Contractor:
Subcontractor
Work Items/activities to be verified Reference Initialled/O Comments
K
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
I have carried out all necessary inspections and verify that the above work for this work area Name:
has been completed and conforms to the contract specification/documents Signature:
Date:
EXAMPLES
Inspection and Test Plan
Customer: INSPECTION AND TEST PLAN for: PAINTING
Contract Number: Work area: (Insert work area)
Contract/Project Name:
Ref Operation or stage of work Stage/ Records Requirement/ Acceptance Inspection/ Inspection *what/who
Description Characteristics frequenc standard/ criteria test Employee Service Customer
y specification procedure provider
1 Incoming Conform to Each Delivery Orders as GPC Check H W
materials order delivery dockets/ placed approved & against
inspection Checklis colour orders
t sched.
2 Storage and As specified Each Checklis Specification, Safe, Visual X S S
protection week t as attached secure/
adequate
protection
3 Preliminary Task Each Checklis Specification, All tasks Visual H W S
activities completion work t as attached, completed
area WHS practice
& Regulation
4 Surface Ready to paint, Each Checklis Specification, Smooth Visual H H W
preparation clean and work t as attached and clean
smooth area
5 Painting Full & uniform Each Checklis Specification, Checklist Visual X S, H(C) S
cover, smooth, work t as attached and test
colour area panel
6 Pre-handover All matters Each Checklis Specification, Completed Final H H H
activities finalised, clean work t as attached to spec/ inspection
and tidy area clean and
tidy
*W = Witness Point; H = Hold Point; H(A) = Inspection/Test by Authority; U(C) = Inspection/Test by Consultant; S = Surveillance or monitoring;
X = Self inspection by performer of work.
*W = Witness Point; H = Hold Point; H(A) = Inspection/Test by Authority; U(C) = Inspection/Test by Consultant; S = Surveillance or monitoring;
X = Self inspection by performer of work.
Customer:
Contract Number: INSPECTION AND TEST PLAN for: CIVIL CONCRETE WORK
Project Name:
Stage/ Requirement/ Acceptance Inspection/ test
Ref Operation or stage of work Records Inspection *what/who
frequency standard/ criteria procedure
Description Characteristics specification HADI Representative
1 EARTH WORK
Area Marking for To IFC Correct
1.1 Each Area - Submit details H H
Excavation specification Drawing Marking
To
1.2 Backfilling Each Layer - - 150-300mm Visual H W
specification
Prestart ASTM D 1556
To
1.3 Compaction concrete Checklist or 95% Third Party Test W W
specification
work ASTM D 2557
2 CONCRETE WORK
Rebar: Size,
Numbers,
Form &
To IFC Hooks & Laps
2.1 Reinforcement Each Work - Visual / Measure H H
specification Drawing Form: Visual,
works
Dimensions &
Straight
IFC Specification/
Task Correct
2.2 Concrete Pouring Each pour Drawing & drawings, as Visual X W
completion Placement
Checklist attached
Workability of Each Attached 100 mm
Slump test ASTM C 143 Measure H W
mix delivery record ±25mm
Concrete test Concrete Test lab 30 Mpa
2 per pour ASTM C 39 Thirty Party Test H W
cylinder strength certif. minimum
As per
Concrete As per ACI Attached
Maturity Check ASTM C 1064 Approved IFC Thirty Party Test H W
Temperature test requirement record
Drawing
To Finish/ curing/
3 Stripping & curing Each pour Checklist - Visual X W
specification maintained
Waterproofing for To
4 Each Work - Visual X W
Foundation specification
All matters Completed to
Pre-handover Final visual
5 finalised, clean Each pour Checklist - spec./ clean H H
activities inspection
and tidy and tidy
*W = Witness Point; H = Hold Point; H(A) = Inspection/Test by Authority; U(C) = Inspection/Test by Consultant; S = Surveillance or monitoring; X = Self
inspection by performer of work.
Customer:
Contract Number: INSPECTION AND TEST PLAN for: PIPING WORK
Project Name:
Stage/ Requirement/ Acceptance Inspection/ test
Ref Operation or stage of work Records Inspection *what/who
frequency standard/ criteria procedure
Description Characteristics specification HADI Representative
1 SPOOL MAKING (SHOP)
Cutting & Bevelling
of each Parts & To IFC Correct
1.1 Each Line ASTM B31.3 Visual H W
Check of specification Drawing Marking
identification
To IFC Correct
1.2 Fit up of Spools Each Line ASTM B31.3 Visual / Measure H W
specification Drawing Marking
Monitoring of To
1.3 - Checklist ASTM B31.3 - Visual W W
Welding specification
To IFC with
1.4 Final Inspection Each Spool ASTM B31.3 Size of Pipe Visual / Measure X W
specification Checklist
2 FIELD ASSEMBLY
Inspection of
To IFC
2.1 internal cleanness Each Work ASTM B31.3 - Visual H H
specification Drawing
prior of installation
Task Random IFC Correct
2.2 Fit up ASTM B31.3 Visual / Measure H H
completion check Drawing Placement
Check that no
Attached
2.3 Stresses on Spec. Each Spool ASTM B31.3 - Visual X W
record
Installation
2.3 Surveying Spec. Each Line ASTM B31.3 - Surveying Report H R
Daily
Monitoring of
2.4 WPS / Spec. Each joint Welding ASTM B31.3 - Review / Check H W
Welding
Report
NDT
2.5 NDT Spec. 10% Random Request ASTM B31.3 Third Party W W
Report
2.6 Pipe Support IFC - DRG - H R
Line Check (Punch
IFC
2.7 list acc. To WPS / DWG Each Line Spec. - Check List H H
Drawing
Isometric)
1.5 Times of Pressure test
2.8 Pressure Test Each Line ASME VII H R
Line Pressure report
IFC Valve Installation
2.9 Valve Installation IFC Required line - H W
Drawing Report
IFC
2.10 Final inspection Spec. - - - Check List X H
Drawing
*W = Witness Point; H = Hold Point; H(A) = Inspection/Test by Authority; U(C) = Inspection/Test by Consultant; S = Surveillance or monitoring; X = Self
inspection by performer of work.
Checklist
INSPECTION AND TEST PLAN CHECKLIST for: PAINTING
(To be completed by the person(s) directly responsible for the work)
Contract Number: Work area: Checklist Number:
Contract/Project Name:
Contractor:
Subcontractor:
Work Items/activities to be verified Reference Initialled/O Comments
K
Preliminary Access permission obtained
activities Access obtained
Equipment approved/on site -
Scaffold/ladders
Signage/barricades
Brushes/rollers/drop sheets
Materials approved/on site -
Filler/thinners
Paints/colours
Repairs completed
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
Surface Notification of power disruption
preparation Protective measures
Isolate appropriate circuits
Filled correctly
Free of oil/grease
Free of dirt and loose particles
Sanded smooth
Washed down
Spot primed
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
Painting Humidity/temperature appropriate
Protective measures
Paint applied to manufacturer’s instructions
Each coat free of imperfections such as
runs, patchiness, pinholes, misses etc.
Drying time between coats appropriate
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
Pre-handover Replace fixtures
activities Touch up
Remove protective measures
Final inspection confirms conforming
Remove scaffold/ladders, clean up etc.
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
I have carried out all necessary inspections and verify that the above work for this work area Name:
has been completed and conforms to the contract specification/documents Signature:
Date:
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
Pre-start Fixtures removed
Protective measures
Install temporary power (where necessary)
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
Carry out work Apply safety procedures at all stages
Protective measures
Carry out work as per specification, AS 3000
and other relevant codes
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
Pre-handover Carry out all testing and safety checks
activities Restore power supply to all isolated circuits
Remove temporary power supply
Remove protective measures
Final inspection confirms conforming
Remove scaffold/ladders, clean up etc.
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
I have carried out all necessary inspections and verify that the above work for this work area Name:
has been completed and conforms to the contract specification/documents Signature:
Date:
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
Stripping & curing When stripped
Repairs
Curing method
Curing maintained ………….. days
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
Pre-handover Finish
activities Levels/ dimensions
Equipment cleaned and site clean
Test results for concrete cylinders
I have carried out all necessary inspections and verify that the above items/activities conform Name:
to the contract specification/documents Signature:
Date:
I have carried out all necessary inspections and verify that the above work for this work area Name:
has been completed and conforms to the contract specification/documents Signature:
Date: