Project Quality Plan

"Construction of Interchange cum Road Over Bridge (ROB) at

LC-236 (Kutch Salt Junction) on NH-141 (Phase-I) in the State
of Gujarat under EPC mode"

Project Quality Plan

Revision No.: rv_no

DOCUMENT RELEASE AUTHORIZATION

Originated by : ______________________

Approved by : ______________________

Approved by : ______________________

Issued as: CONTROLLED COPY / UNCONTROLLED COPY for information purpose

(Appropriate status to be highlighted)

“This document is a property of Patel Construction Company, and is not to be reproduced, copied, handed
over to a third party or used for any purpose other than that for which it has been loaned”.

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TABLE OF CONTENTS

Title Page No

1.0 PURPOSE................................................................................................................................................4

2.0 PROJECT QUALITY POLICY:..............................................................................................................4

3.0 PROJECT QUALITY OBJECTIVES:....................................................................................................4

4.0 SCOPE OF SERVICES:.........................................................................................................................5

5.0 DEFINITIONS:.........................................................................................................................................6

6.0 DOCUMENT AND RECORD CONTROL SYSTEM:..........................................................................8

7.0 PROJECT MANAGEMENT:.................................................................................................................11

8.0 QMS ORGANIZATION:.........................................................................................................................12

9.0 PRODUCT REALIZATION PROCESS:..............................................................................................21

10.0 PROCESS CONTROL SYSTEM:.......................................................................................................28

11.0 HANDING OVER OF WORKS:..........................................................................................................32

12.0 CONTROL OF NON CONFORMING PRODUCT(S)/PROCESS(S):............................................33

13.0 TRAINING:...........................................................................................................................................37

14.0 DISTRIBUTION LIST:.........................................................................................................................37

15.0 LIST OF ATTACHMENTS:.................................................................................................................37

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History of Revisions

Chapter/clause
Revision Revision
No. & text Reason for revision
No. date
affected

rev_no_1 rev_dt_1 rev_cl_1 rev_res_1

rev_no_2 rev_dt_2 rev_cl_2 rev_res_2
rev_no_3 rev_dt_3 rev_cl_3 rev_res_3
rev_no_4 rev_dt_4 rev_cl_4 rev_res_4
rev_no_5 rev_dt_5 rev_cl_5 rev_res_5

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1.0 PURPOSE:
This project specific quality plan defines the Quality Management System of project
management, engineering & design, procurement, construction and commissioning
functions to comply with the requirements of contract document of Construction of
Interchange cum Road Over Bridge (ROB) at LC-236 (Kutch Salt Junction) on NH-141
(Phase-I) in the State of Gujarat under EPC mode.

Brief Particulars:

Project: Construction of Interchange cum Road Over Bridge (ROB) at

LC-236 (Kutch Salt Junction) on NH-141 (Phase-I) in the State
of Gujarat under EPC mode.

Client INDIAN PORT RAIL & ROPEWAY COPRORATION LTD

Independent
Engineer
Concessionaire
Contractor Patel Construction Company.

2.0 PROJECT QUALITY POLICY:

It is policy of Patel Construction Company -PCC to establish quality excellence in order to
achieve Customer satisfaction in Construction of Interchange cum Road Over Bridge (ROB) at
LC-236 (Kutch Salt Junction) on NH-141 (Phase-I) in the State of Gujarat under EPC mode , while
engineering, constructing, commissioning and handing over of the project components so as
to ensure the successful operation and performance of this project. Work shall be executed
in good compliance with safety requirements without causing undue pollution to the
environment in the vicinity of project and other areas of operation.

3.0 PROJECT QUALITY OBJECTIVES:

 Understanding the project requirements/features in totality

 Assessing the impact of environment on quality
 Developing quality systems to ensure that the process and product fulfill quality
requirements consistently
 Assignment of responsibilities with absolute clarity
 Establishing methods for meaningful evaluation
 Establishing documentation processes and systems to minute details
 To ensure proper establishment of project management function and co-
ordination among engineering, design, procurement and construction functions
for achieving customer satisfaction.
 To ensure effective communication between the joint venture partners if any.
 To ensure completion of Project stages without compromising of Quality and
HSE issues, within the budget and stipulated time.
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 Construction with quality which will ensure the satisfaction of Customer.

 To improve the work environment by developing team work, leadership, quality
and effective communication.

4.0 SCOPE OF SERVICES:

 Engineering of Civil works related to Major and Minor Bridges, Pipe culverts, slab
culverts, Arch Culverts, Stone slab culverts, Box Culverts, Highway(Earthwork,
Pavement courses), Drain, Grade Separators, Bus bays and bus shelters, Truck
bays etc.

 Maintenance of the project for a period as specified in the Contract after

Successfully completion of the project.
 Providing various project facilities as specified in the contract.
 Project Completion documentation and handover.

5.0 DEFINITIONS:

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In the context of this project quality plan the following abbreviations, words or
phrases will be assigned to them:

Client INDIAN PORT RAIL & ROPEWAY COPRORATION LTD

Concessionaire
Contractor Patel Construction Company -PCC
Vendor / Supplier Agency engaged to supply of materials,
Quality Degree to which set of inherent characteristics fulfills
requirement
Quality Policy The overall quality intentions and directions of an organization
as regards to quality as formally expressed by top
management
System set of interrelated or interacting elements
Quality Management Coordinated activities to direct and control an organization with
regard to quality
Quality Planning A document setting out the specific quality practices, resources
and sequence of activities relevant to a particular product,
project or contract
Quality Objectives Something sought, or aimed for, related to quality
Quality Control part of quality management focused on fulfilling quality
requirement
Quality Assurance All the planned and systematic activities implemented within
the quality system and demonstrated as needed to provide
adequate confidence that an entity will fulfill requirements for
quality
Non-Conformity Lapse in either discipline or control, of a requirement of own
system / standard.
ITP Inspection and Test Plan
PQP Project quality plan is the key document providing guidance to
achieve compliance with project specifications. It identifies the
project management processes, quality management
practices, resources and sequence of activities relevant to a
particular project / contract.
CM Construction Methodology is subset of PQP and a supporting
document which describes the specific construction methods /
practices, resources deployment and sequence of activities
and proposed quality assurance / control measures / plans etc.
Construction methodologies will be specific in nature for each
specific service / activity. It shall be developed for critical
activities involving different processes.
Competence Demonstrated personal attributes and demonstrated ability to
apply knowledge and skills
Customer Customer’s perception of the degree to which the customer’s
satisfaction requirements have been fulfilled
Requirement Need or expectation that is stated, generally implied or
obligatory
Product It is defined as result of process
Process It is defined as set of interrelated or interacting activities which
transforms inputs into outputs.

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Effectiveness Extent to which planned activities are realized and planned

results achieved
Efficiency Relationship between result achieved and the resources used
Procedure Specified way to carry out an activity or a process
Repair Action on non-conforming product in order to make it confirm
to requirements differing from the initial ones
Concession Permission to use or release a product that does not confirm to
specified requirements
Deviation Permission to depart from the originally specified requirements
of product prior to realization

APPLICABLE DOCUMENTS AND REFERENCES:

Table - 1
S
Description of Document Reference No.
#
Quality Management System:
1 ISO 9000
Fundamentals and vocabulary
Quality Management Systems –
2 ISO 9001
Requirements
Guidelines for performance
3 ISO 9004
improvements
4 Contract documents CA
Manual for Quality Control in Road and
5 IRC SP 112
Bridge Works
Manual of specifications and standards for
6 IRC SP 73
two laning of highways with paved shoulders
7 Specifications for Road and Bridge Works MORT& H
Dimensions and weights of road design
8 IRC 3
vehicles
Standard Specifications and code of
9 practice for road bridges, Section-I- General IRC 5
features of design
Standard Specifications and code of
10 practice for road bridges, Section-II- Loads IRC 6
and stresses
11 Type designs for Highway Kilometre Stones IRC 8
12 Traffic Census on Non-Urban Roads IRC 9
13 Type Designs for Boundary Stones IRC 25
14 Type Designs for 200- Metre Stones IRC 26
15 Code of practice for road markings IRC 35
Guidelines for the design of flexible
16 IRC 37
pavement
17 Code of practice for Road signs IRC 67
Geometric Design Standards for Rural
18 IRC 73
( Non-Urban Highways)
Standard specifications and code of practice
19 for road bridges, Section VII- Foundation IRC 78
and Substructure
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Recommended Practice for Road

20 IRC 79
Delineators
Tentative Guidelines for Strengthening of
21 Flexible Road Pavements using Benkelman IRC 81
Beam Deflection Technique
Standard specifications and code of practice IRC 83 ( Part I, II
22
for road bridges, Section IX- Bearings and III)
Guidelines for the design of Interchanges in
23 IRC 92
Urban Areas
24 Guidelines for Pedestrian facilities IRC 103
Manual for Survey, Investigation and
25 IRC SP 19
Preparation of Road Projects
26 Vertical Curves for Highways IRC SP 23
Guidelines for Inspection and Maintenance
27 IRC SP 35
of Bridges
Guidelines of Design of At- Grade
28 IRC SP 41
Intersections in Rural and Urban Areas
29 Guidelines on Urban Drainage IRC SP 50
30 Guidelines for safety in construction Zones IRC SP 55
Applicable BIS / BS / ASTM and other
31 ---
codes / standards

6.0 DOCUMENT AND RECORD CONTROL SYSTEM:

6.1 Document Preparation and Approval:

The process user will study the process requirements and specifications, prepare
procedure / guidelines / work instructions as per the corporate directive guidelines
and obtain the document no. from the document controller to codify the document.
After preparation of the document the originator will send the document for approval
to the approving authority. After the document is approved, it will be finally cleared
by the reviewing authority for issue. Issue to all documents to concerned users shall
be controlled and recorded by Planning.

6.2 Document Issue and Control:

The following steps will be followed for document issue & control:

A. Drawings and other project specific documents received from the client
/Consultant / Contractors and its associates:

Step-1 Head of function / PM will study the document and decide to whom it should
be distributed.
Step-2 The planning at site will first enter the details in document master list and
take the number of copies required and prepare a document distribution list in a
register.
Step-3 Planning will put the “Controlled Copy” stamp and also the copy no on each
copy and issue to the identified users. When a revised document is issued, it will be
ensured by the document controller that the superseded documents are withdrawn
from all points of use and destroyed. In cases where superseded document has to
be preserved for record, the same shall be kept separately after putting
‘SUPERSEDED’ stamp on it.
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Step-4 Planning will maintain issue control register including its distribution.
Relevant details regarding document title, document number, issue (Revision /
Edition), Date of receipt & issue of the document in the distribution register,
signature of the recipient shall be taken on the document issue register as an
evidence of receipt of the document.

B. System documents like manuals, procedures, guidelines and formats etc,

received from Corporate Office:
These system documents are sent in soft copies to the planning at site in ‘Read
Only’ format. The document controller, in turn, distributes these documents to all
concerned users through LAN/e-Mail and maintains record of distribution. When
such documents are revised, holders of soft copies shall ensure that the
superseded version is deleted from the computer and send such confirmation to the
document controller.

In cases where hard copies are required for distribution, the control shall be
exercised as stated in Steps 2 to 4 in para A above.

C. Documents like drawings, procedures, methodologies, ITPs etc. generated at

the project site:

These documents shall be handed over to planning by the originator after

necessary approval and review by competent authorities and with the proposed
distribution list. There after the planning will follow the steps 2 to 4 above.

6.3 Document Amendment:

In case the documents require any amendment, an amended document will be
prepared with appropriate revision number. The revised approved document shall
be sent for review of the competent authority. The same process of document issue
and control shall be followed as far regular drawings / documents are concerned. All
the obsolete documents will be removed and destroyed ensuring that they are not
used erroneously.

6.4 Record Control System:

All the records required as per contract requirements and to demonstrate the
effective operation of the quality management system are identified by the pertinent
department / personnel.

All the records identified will be codified to ensure proper identification and
traceability of the record as per the guidelines on document codification.

Format of the record will be designed and approved by Project Manager for
capturing the information in structured fashion, with easy traceability.

Each department will prepare a department wise master list of record incorporating
the record no., name of the record, location of the record, retention period etc. for
effective control of all the pertinent records. Department head will ensure that the
records used in the department will be legible, readily identifiable and retrievable
and will be maintained in secure conditions at appropriate locations to minimize
damage and deterioration.
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After the retention period for a file / register is over the record will be disposed and
new file / register for the same purpose will be created.

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6.5 Control of Documents / Specifications / Drawings of External Origin:

All the documents / drawings of external origin i.e., issued by client / engineer or
any other relevant statutory / regulatory bodies etc. will be received and registered
in the appropriate document receiving register with proper document code, revision
and date of receiving status. Distribute / issue to the pertinent user, after due entry
in the register and obtaining the signature of the recipient. Whenever the
amendments or the amended version of the documents or drawings are received,
the same will be registered in the register. The earlier document / drawing will be
stamped “SUPERSEDED” in red color and the amended version(s) issued to the
pertinent user against acknowledgement after noting therein revision no. of the
documents before issue.

7.0 PROJECT MANAGEMENT:

PCC will ensure proper co-ordination between Design, Construction and Procurement for
the project;

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8.0 QMS Organization

8.1 Project Organizational Structure:

Project Director is an interface between various HO Service departments and their

relevant departments at Project site and will ensure that all the Project
requirements / services are extended from HO in a systematic and effective
manner. Project Manager is responsible for entire Project Operations and shall
interact with Client / Consultant / Execution Head / other involved agencies in all
project related matters, policies, systems etc.

8.2 Project Management Activities:

 Detailed Planning of Independent Activities

 Project Programming
 Project Resourcing and Purchase Planning
 Allocating the responsibility and authority
8.2.1  Interaction with client during project phases and
Management of processes.
project
 Interaction and coordination with design
agencies, Sub contractor, Major suppliers of the
materials for civil construction and mechanical,
electrical components of the project.
 Mobilization of resources.
 Project Quality, Safety and Environmental
Management System Planning

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 Overall Engineering and Design Programming

for Detailed engineering of all components of
project
8.2.2
 Pre- qualification and selection of consultants,
Management of
external design agencies, if required.
Engineering and
Designs  Consultants/External Design Agencies
engagement and monitoring
 Planning the sequence of Design and
Engineering Services during project phases
 Coordination among external agencies,
subcontractors and suppliers during different
phases of Project.
 Design Review and validation
 Coordination with procurement, construction
and preparing commissioning, operation
procedure

 Plan, Programme and coordinate procurement

activities as per detailed engineering Spec.,
Drgs.
8.2.3  Establishing criteria for verifying purchased
Management of products, components including at supplier
Procurement premises.
 Evaluating logistic requirements
 Issue the purchase orders, contracts and
technical services agreements
 Warranty/Replacement for non-conforming
purchased product

 Construction Planning of the project

 Construction Coordination , coordination with
design agencies for design verification and
validation
8.2.4  Implementation of construction Methodology,
Construction Procedure and Controls including the execution
Management plan, Quality Management Procedures and
Engineering Design.
 Implementation of EHS requirement at site
 Supervision of Subcontractor’s activities.
 Perform Pre-commissioning activities.
 Develop Check List for completion of different
activities

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8.3 Assigned Duties and Responsibilities of ‘Project Management

Functions’:

8.3.1 Key Responsibilities of ‘Project Manager’

 Approve project execution work plan and budget

 Communicate salient features of the project, roles, expectations, KRAs to the
project team
 Depute all Dy. Managers / Managers having degree / diploma in Civil Engineering
with relevant experience.
 Site organization shall ensure that adequate number of Engineers / Managers are
deployed to provide complete coverage and effective management of all activities.
 Ensure on time in full project delivery as per the project plan
 Ensure compliance to statutory requirements with the assistance of Contracts Head
 Build & maintain effective working relationships with external entities- client, other
contractors, Govt. agencies, local community etc.
 Monitor resource productivity, physical and financial progress in consultation with
Project Controls
 Ensure adherence to contract specifications, HSE and quality standards
 Prioritize and resolve conflicting issues on the project in consultation with Execution
head.
 Plan and ensure adherence to mobilization/ demobilization of resources with
Project Controls
 Conduct weekly/monthly review meeting, develop action plan and monitor as per
structured agenda covering Quality, HSE, Planning (Resource & Manpower), legal
requirements etc..
 Ensure that all functions at the project site are appropriately staffed, trained and
managed.
 Define and monitor performance targets for the project team.

8.3.2 Responsibility of the “Highway/Structure Manager:

 Execute project works as per contract specifications, schedules and milestones.
 Implement the performance targets set for the project execution team and ensure
delivery
 Review Daily Progress and implement corrective actions as needed &/or as
suggested by Project management & Controls.
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 Ensure coordination amongst agencies.

 Be a part of the project leadership team and ensure performance by all project
functions.
 Implement project programs to improve productivity and reduce costs.
 Ensure that quality parameters and HSE norms are complied with during project
execution.
 Interact with Client and all external stakeholders in the project as required and
resolve issues if any.

8.3.3 Responsibilities of the ‘Planning Manager:

 Develop WBS along with Project head, plan project milestones, determine
resource requirement, propose deviations in productivity norms as per site
conditions, and prepare supplier schedules and initial project plan.
 Prepare project annual/ monthly/ daily work plan and budgets in consultation with
Project Head.
 Ensure timely and accurate planning, scheduling and expediting of resources and
adherence to productivity norms
 Resolve all issues and queries which are escalated by the project execution team
 Monitor & report actual project performance against budgets & raise an early
warning on non-achievement of targets.
 Implement the contracts appreciation document and ensure adherence to
contractual conditions
 Develop and maintain client relationship
 Ensure timely & accurate work measurement, billing, certification and collection
 Ensure identification, documentation and submission of claims & variations.
 Ensure documentation for Dispute Review Boards & arbitration
 Ensure effective claims and recovery management
 Validate contractual letters to be sent to Client/ Contracts Head- HO
 Finalize sub contractor engagement, scope of work, rates (including rates for
variations)
 Ensure validation of subcontractor’s bills as per contract conditions, including
reconciliation of material/ quantities

8.3.4 Responsibilities of the ‘Quality Manager’:

 Implementation of Quality Management System & Project Quality Plan (PQP) in
the Project Site.
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 Responsible for Quality Planning, Control, Assurance and Improvement

 Prepare / Review Construction Methodology, Inspection & Test plans and getting
the same approved by PM after consultation with Corporate Office.
 Deputing QA/QC Engineers at various areas of operations / activities.
 Interaction with Clients / Consultants regarding Q.M. Procedures’ approval &
implementation, material selection / testing & approval.
 Reporting to Head-Quality (HO) regarding the performance of Quality Management
System at the relevant Project Site.
 Prepare project handing over document related with Quality as per established
system to Quality Management.
 Maintenance of test records for various activities as per ITP & QAP.
 Inspection of field activities as per approved inspection plans, obtaining clearances
from clients / consultants and making reports, issuing NCR’s and closing after
corrective / preventive actions.
 Reporting to the project manager regarding Quality performance
 Co-ordinate with stores team to plan inspection & testing of raw materials.
 Coordination the Inspection of all Incoming material and prepare Rejection & rework
report.
 Coordination of In-process Inspection at Crushing plant, Quarry, Batching plant,
Wet Mix Plant etc. and prepare Rejection & rework report.
 Setting up of field laboratories
 Calibration of equipments
 Preparation of JMF for flexible pavement and concrete mix design
 Coordination of In-process Inspection & testing at work activities like soil
compaction, concrete pouring, piling etc. and prepare Rejection & rework report.
 Issue Product quality NC and coordinate implementation of CAPA.
 Analysis and CAPA to Customer Complaints

 Carry field testing of materials/ works as per approved ITPs, obtains approvals from
Client / Consultants and record the testing activities in approved formats, maintain
the same.
 Coordination with Execution team during testing of Materials/works and suggest
necessary Corrective & Preventive actions to control the Nonconforming
products/process.
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 Preparation of Project Handing over documents related with quality .

8.3.4.1 Responsibilities of the ‘Quality Engineer’:
 Assisting Quality Manager in setting up the field laboratories
 Day to day supervision of works of lab technicians
 Ensure proper calibration of all laboratory equipments
 Preparation of JMF for flexible pavement & concrete mix Design
 Conducting laboratory and field tests on random basis
 Calculation of test results from test observations carried out by lab technicians
 Maintaining respective records
 Selection of borrow areas
 Periodical checking of calibration of WMM plant, Hot mix plant, Batching plants
 Preparation of summary test results for monthly progress report
8.3.4.2 Responsibilities of the ‘Lab Technician:
 Sampling of construction materials and preparation for testing as per IS code
 Conducting laboratory test of aggregate, cement, soil, bitumen and other
materials
 Recording of test observations
 Inspection of batching plant, hot mix plant and WMM plant at the time of
production
 Conducting field tests at site and recording test observations
8.3.5 Responsibilities of the ‘HSE Manager’:
 Implementation of Occupational Health & Safety and Environment management
System at project site.
 Carryout hazard identification and risk assessment of all activities and recommend
required control measures.
 Ensuring that all HSE measures and applicable Legal issues for the project are
complied with throughout the duration of the contract including implementation of
revisions.
 Reporting to Head-HSE on HSE issue .
 Maintaining relevant records on HSE issue.
 Ensuring that all personnel engaged at the project receive induction training, prior
for their respective job allocation.
 Interact with client / consultants regarding all HSE issues pertaining to project

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 Advise the project management and line management in planning and organizing
measures necessary for establishing safe work environment towards preventing
accidents.
 Investigation of incidents including, fatal accidents, dangerous occurrences, near
misses and taking remedial measures and furnishing reports to EHS Head on the
above
 Provide training on HSE related subjects to all in association with concerned
departments.
 Ensure Constitution of site HSE committee, and carrying out periodical (fortnightly /
monthly) walk down by HSE committee to identify critical areas of deficiency and
take necessary corrective preventive actions. Ensure discussions on safety in the
HSE committee meeting and define action plan.
 Conducting Inspection of Plant & equipment and Fire fighting & Safety Appliances /
Equipment Tools & Scaffolding etc. to suggest corrective measures for safe
operation.
 Ensure the effective monitoring & control measures of the environment as per
Environment management plan by engaging external monitoring agencies.
 Raising of Non-Conformities on Safety & Environmental issues.

8.3.6 Responsibility of the ‘Designer’ / ‘External Designer’

The responsibility of designers typically include the following, as applicable
 Co-ordinate among JV designers to manage design interfaces among JV partners if
any.
 Agree with design scope of work between JV design departments if any.
 Clarify with management of design function regarding design input and output
requirements.
 Agree with management of design function the design validation
requirements. Design validation like: NDT etc.
 Prepare and implement quality plan for performance of design & engineering.
 Implement appropriate elements of project quality plan, and construction
methodology as defined by
 Identify design inputs and review them for adequacy, completeness and relevance,
including those related to regulatory requirements and legitimate community
expectation, and advice management of design function of their adequacy or
otherwise.
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 Prepare design brief to engage subcontractors and identify the inter-actions

required.
 Resolve and coordinate design input required by external design agencies.
(Including design innovations).
 Co-ordinate between outputs from external design agencies and input to Suppliers
regarding specification of material, equipment / machineries etc.
 Participate in inter-discipline or inter project function reviews.
 Verify suitability of design & engineering output to meet requirements of contract
specifications.
 Prepare, review, approve and issue specification and drawings to procurement and
construction.
 Review suppliers’ and sub-contractors’ work methods and verification plans to
confirm that these are adequate to meet design & engineering intent.
 Participate in the verification at suppliers’ premises or at site to determine whether
the supplied materials, equipment / machineries meet the design and engineering
intent.
 Perform design validation if required.
 Manage non-conformance and improvements of the designer function.
 Acquire the required quality records, including those from external designers.

8.3.7 Responsibilities of the ‘Manufacturer / Supplier’:

The responsibilities of the supplier function typically include the following, as

applicable:

 Agree with management of procurement function any validation requirements for

material, (e.g. type testing of manufactured goods).

 Ensure that the delivered material, equipment / machinery is as per engineering

specification or drawing.

 Implement appropriate elements of project quality plan and construction

methodologies.

 Seek acceptance of design as meeting project design intent.

 Prepare specification for the supply of parts, components and / or material that
identifies the interaction required and gives details of the appropriate elements of
the construction methodologies.

 Manage non-conformance and improvements of the supply function.

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 Acquire required quality records, including those from sub-suppliers.

 Manage handling, storage, preservation and transport considerations

8.3.8 Specific Responsibilities:

Quality management group @ HO - For Preparation of PQPs in

Consultation with relevant Project
Team
Manager / In-charge QM Dept. at Site - For Preparation of Construction
Methodologies
Project Manager - For Review of PQPs, Construction
Methodologies.
Quality Head @ H.O - For Approval of PQPs, Construction
Methodologies
Project construction function - For implementation of PQP,
Construction Methodologies.

8.3.9 FUNCTIONS AND RESPONSIBILITIES OF DELEGATED AUTHORITIES:

 The delegation of responsibilities for key authorities such as Project Manager
would be given to Next Senior in his absence.
 Further delegation within the Management Function would be done by the Project
Manager considering the project specific requirements and ability to carry the
responsibilities of the suitable delegated person.
 The function of delegated person should be same as that of the main authority (of
which the responsibilities are delegated) in his absence.
 The delegated person is empowered to take decisions as and when required
within his limits of authority, to achieve planned production, within the contractual
provisions.
 No person is authorized to approve any deviation from Project Specification which
may affect end quality of our product. Only concession request with required
controls in place can be obtained in exceptional cases where limitations exist.

9.0 PRODUCT REALIZATION PROCESS:

9.1 Project Quality Assurance and Quality Control System:

Project Quality Management includes the processes required to ensure that the
project will satisfy the needs for which it was undertaken.

9.1.1 Quality Assurance:

Quality Assurance system comprise of:

 Organizational Structure, Responsibilities and Authorities, Construction Planning,

Scheduling and Monitoring, Design Management, Project Procurement
Management, Project Sub-contract Management and Document & Record
Control.
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 Established Project Documents viz., Quality Plans for various activities, Work
Procedures, Inspection & Test Plans, Formats etc.
 Control of measuring and monitoring equipment
 Internal Quality audit at regular interval and
 Other aspects of Quality Assurance like:
a. Control of Nonconforming Products or Process
b. Analysis of measurement data followed by corrective actions
c. Management Review of Project Performance.

9.1.2 Quality Control:

Various Project Quality Control aspects (to control the quality of project products)
include the following:

 Organization of Quality Control Department.

 Identification of Sources for various incorporated Materials.
 Testing of selected materials for pre-qualification and during routine execution of
works to find the suitability/compliance to standards, specifications etc.
 Periodic inspection and testing as per established Inspection & Test Plans.
 Establishment and Maintenance of Field Laboratories for testing of materials
 Calibration of all testing equipment and measuring instruments.
 Maintaining relevant Quality Control results.
 Analysis of various Quality Control data, checklists, graphs and other data for
quality improvement.

Compliance is required as per relevant standards like MoRTH, IRC, BIS, BS, ASTM and
AASHTO. Any exceptions require prior approval.

9.1.3 Organizational Structure of Project QMS department:

Project Quality department shall consist of Project QA/QC Head/ Engineers,
administratively reporting to Project Manager and functionally to the Head - Quality
at Corporate Office. The organization structure of project QMS department is shown
in attachment.

The Project QA/QC Head / Engineer reports and takes action as per the directions
of Project Manager/functional head at HO. The Project QA/QC Head / Engineer is
primarily responsible for effective administration of entire project quality
assurance/control activities and plays a pivotal role in liaison with
Client/Consultants/Sub-contractors/Vendors and other project involved agencies in
all Quality Management related matters such as finalization of relevant Method
Statements/Procedures, Inspection & Test Plans, Inspection/Testing procedures
etc.

Project Lab technicians assist QC Engineers in fulfilling all Quality Control

requirements. They report to Engineer on day-to-day Quality Control activities at
respective work areas.

9.2 Detailed Design and Engineering Procedure

9.2.1 Process for planning for Design and Engineering

The process of design and Engineering is determined by the WEL on the

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 Project Quality Plan

following:
 Design stages.
 The process of review, verification and validation that is appropriate to each
design stage.
 Assigning responsibilities for design
 A system of communication to all the interfaces between the different groups
involved.
 A system to update the planning output, as appropriate, as the design progress.

9,2.2 Process for determining and reviewing of the design and Engineering Inputs.
The various inputs as mentioned below will be taken into account while carrying
out basic engineering at preliminary stage:

 Functional and performance requirements as per Project Specification.

 Applicable statutory and regulatory requirements.
 Information derived from previous similar design & previous functional
experience from similar type of projects.
 Applicable Codes & Standards.
 The detailed inputs and design parameters which will be considered to carry out
detailed Design and Engineering are as follows:
 Detailed lab & field investigation reports as geological, hydrological,
environmental and other issues vital to the design.
 In situ stress parameters
 Appropriate Design parameters & site specific information.
 Construction / Erections
 Performance Criteria.

These inputs will be determined and reviewed for adequacy, completeness, and clarity
without being ambiguous, and not in conflict with each other.

9.2.3 Process for determination of output of Detail Design and Engineering

Design and Engineering output will,
 Meet the input requirements for design.
 Provide appropriate information for procurement, production/product
realization and for service provision.
 Give Detail Drawings, Specifications etc.
 Contain or a reference to acceptance criteria.
 Specify the characteristics of the Civil, components that are essential for its proper
use and be made in a form that enables verification against the design and
Engineering input and this is reviewed and approved before construction starts.

9.2.4 Process for Design and Engineering Review:

The reviews of design will be performed systematically at suitable stages.

A schedule for Design Review will be prepared and accordingly the review will be
done by competent Authority. Whenever external design agencies are engaged, the
schedule for design and design review will be prepared by the external agency.
Wherever so stipulated final Detail Engineering, Design, Drawings and specification
will be issued to Client for review before approval and acceptance for issuing them to
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 Project Quality Plan

site for construction. Records of the results of reviews and any necessary actions will
be maintained.

9.2.5 Process of Design and Engineering verification:

The design and Engineering verification will be performed to ensure that the design
and Engineering outputs have met the design and Engineering input requirements
functionally acceptable, operational and safe output for further execution based on
site specific inputs as mentioned in contract specification. Records of the results of
verification and any necessary actions will be maintained

9.2.6 Process of Design and Engineering validation.

The design and Engineering validation will be performed to ensure that the resulting
product is capable of meeting the requirements for the specified application for the
intended use. And validation will be completed to the extent it is practicable, prior to
construction or implementation / installation. Records of the results of validation and
any necessary actions will be maintained.

9.2.7 Process of Control of Design and Engineering changes.

In case of any changes in the design parameters, criteria, and output, such changes
will be identified, reviewed, verified and approved by competent authority of
WEL/client before implementation, if required; this will also include evaluation of the
effect of the changes on the constituent parts and installations already delivered /
completed. No such changes in design / drawings would take place without informing
Project Head and without approval of Execution Head. Records of the results of the
review of changes and any necessary actions will be maintained.

9.2.8 Control of Detail Engineering and Design Output:

The Control of Detail Engineering and Design Outputs will be below:

a. Registration of Drawings, Design & Engineering Specifications, Details:

Drawings will be registered and controlled within project by Planning department.
Master List of Drawings shall be maintained up to date. It will contain Drawing No,
Revision Status, Date of Revision, No of Copies Received, and Date of Receipt. In
addition it shall have information of status related to ‘Good/ Released /Approved for
Construction‘. Master list of Drawing will be updated whenever new revision of
Drawings, Engineering Documents are issued.

b. Issue & Control of Drawings, Engineering Specifications and Details:

Site will maintain a “Drawing/ Document Issue Register “. This Drawing Issue
Register Will contain Drawing No, Rev. Status, No of Copies Distributed, Name of
the Functional Head to whom it has been distributed and Signature of the Recipient.
When a particular Drawing / Engineering Document is issued to Functional Head it
must bear a “Control Copy” stamp on it. The “Control Copy “stamp will indicate
the Control Copy No, Issued To, Date of Issue. And whenever a new revision of
Drawing/ Engineering Document is issued, the old revision will be marked as
“Superseded” by putting a Superseded Stamp on it and will be identified and
kept separately (if Required) from the point of use for reference or otherwise will
be destroyed. Planning shall issue approved Design of permanent item planned to
be executed in next 2-4 weeks shall be made available.
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 Project Quality Plan

9.3 Process of Procurement and Control:

9.3.1Process of Procurement:

9.3.1.1 Selection of Suppliers:

Material Equipment and Components will be procured as per Engineering

Specifications, Drawings. Following steps will be followed for selection of suppliers:

a. For Material:

 Procurement function will ask suppliers to submit samples of required materials as

per mentioned specification details to Project Manager wherever required, along
with technical data such as specification, test certificate, brochure etc.

 Project Quality Department will evaluate the quality of samples and approve them,
as per approved Inspection and Test Plan / Technical Specifications.

 Inspection at Suppliers’ premises will be done if required for selection along with
owner/owner’s representative if he wishes to do so depending on the criticality of
material.

 On the basis of evaluation Project Manager will inform the Procurement Function
the names of the selected supplier with their products, plants or components.

 On the basis of this and commercial terms and conditions, Procurement Function
will release orders for materials as and when requirement arises.

 Material sourcing shall be performed from approved source only. Prior

approval is required for any changes proposed in source.

9.3.1.2 Inspection of Equipment, Material including at Suppliers’ Premises and

Storage:

All incoming materials will be inspected by relevant inspection authority of

Engineering / Procurement / Construction Functions or Third Party as per the
following:

a. Inspection at Supplier’s premises to verify the conformity of the material,

equipment, mechanical / electrical, components with Engineering specification,
Drawings. Non-conforming material, Equipment will be rejected.
b. Inspection at site store for all general store items.
c. Inspection of Raw material
d. In-process and final inspection of material as per MORT&H / IRC Standard.
e. NABL Accredited Third Party Laboratory shall only be used for third party material
testing where ever required as per approved ITP.
f. For any construction activities to be performed RFIs will be raised.
g. Monthly Analysis of rejection / failure of tests will be performed.

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 Project Quality Plan

9.3.1.3 Calibration Schedule:

Sl. Equipment Calibration Level Frequency Type of
No. Certificate
1 Load Measuring In accordane External Yearly By NABL
Devices- CTM, CBR, with ISO 7500: Once accredited
Marshall stability proving part 1 agency at
rings site
2 Length Measuring
In accordane External Yearly By NABL
Devices- Micrometers, with BS EN Once accredited
Calipers, Steel rulers,10002: part 4 agency
Dial gauges In House Quarterly In house
3 Time measuring
Check against In House Annual In house
Devices- Stop watches externally
calibrated
watches
4 Temperature Measuring Relevant External Annually By NABL
Devices- Thermometers, standard accredited
Ovens, Waterbaths agency

5 Weighing Macines- Relevant External Annually By NABL

Balances, Weights standard accredited
agency

6 Plants- WMM, HMP, Manual with Inhouse Quarterly Inhouse

Batching Plant standard weights

9.4 Patel Construction Company Control System:

All the Patel Constraction Company engaged by for execution of either temporary or
permanent works of the Project shall be selected based on their technical and
financial competence.

All Patel constraction Company will have to execute the works as per the Contract
Specifications, detailed Engineering specifications, drawings and conditions provided
to them by the Construction Function as per the direction of Management of
Construction Function.

Various Quality Assurance and Quality Control activities of Patel Constraction

Company Works will be carried out and Monitored by Project Construction Function
team and then by QA Personnel and all necessary test reports / documents will be
maintained.
Patel Constraction Company performance will be periodically evaluated in terms of
Quality and delivery of the products & safety practices as per the work schedule
provided by Construction Function. Sub-Contractors will be removed and
deregistered if their performance is not as scheduled and adversely affects the
objectives of project.

The steps involved in selection, control and evaluation of Patel Constraction

Company are represented by a simple flow chart in the subsequent page.
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 Project Quality Plan

10.0PROCESS CONTROL SYSTEM:

10.1 Controlling Construction Operations:

Process will be controlled by identifying various major activities and preparing

Construction Methodologies for the identified activities for the execution of the
same as per the Contractual & Technical requirements.

Construction Methodologies will describe the procedure for controlling Management

Functions such as for the Engineering, Procurement & Construction,
Commissioning, Operation and maintenance Processes for that particular
activity. Construction Methodologies will consist of Deployment schedule of
Manpower, Material and Major equipment, applicable Inspection and Test Plan for
Quality Assurance and Quality Control of various sub-activities. All relevant Formats,
Reports etc. will be maintained for execution of the same.

The following parameters will be considered in the major activities or segments:

a) Scope of the Major Activity.

b) Sequence of Operation starting from Management Function of Engineering upto
Construction, Training and Commissioning.
c) Approved Construction Schedule, Mile Stones of the Project/activity.
d) Detail Engineering and Construction Methodology
e) Machineries & Materials to be Procured and Used.
f) Division of Work into Work Lots.
g) Characteristics, Tolerance and workmanship standard to be met.
h) Inspection and Test Plans.
i) How the Process will be monitored to ensure its continuing suitability.

Finalized Construction Methodologies shall be reviewed by Project Head at site and

then approved by Quality Head at Corporate for adequacy.

Design approval is the basis of Quality Planning and ensured to be approved in

advance. Approved copy of GFC Drawings shall be made available at all work
locations.

The approved Construction Methodologies shall be followed while carrying out various
construction activities at site. Site QC Head shall verify the sequence, quality and other
aspects during construction with reference to the approved Construction
Methodologies. Procedure / Work Methodology shall be demonstrated through trial
stretches and validated as required.

In addition to Site Quality team, all project engineers are required to ensure that the
defects or deviation in material or workmanship are not tolerated. If not corrected /
improved it shall be bought to the notice of Project Manager. Apart from the criteria

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 Project Quality Plan

mentioned in the Construction Methodologies, the QC Head shall also ensure the
routine quality check up of other aspects such as:
 Keep a track on resources engaged for other non major activities.
 Asses the availability of resources and material for carrying out the activity as per
planned schedule.
 Monitoring of Non Conformities and taking appropriate action to close the same.
 Time to time awareness training to site personnel.
 Training on technical aspects related to any construction activity.
 Co-ordination with Project Head for any inputs/suggestions for improvement.
 Interaction with client’s QC representative to asses their views if any.

The activities in Construction Methodologies shall not be considered as the only

major activities but other miscellaneous activities involved in the project which are not
covered in Construction Methodologies shall also be treated as important activities by
Project Quality Head and shall be monitored on time to time basis. A weightage can
be given to such other activities based on their importance in the project by the
Project QC Head for ease in monitoring.

Project Quality Head shall be responsible for inspection of overall construction

activities apart from those listed in Construction Methodologies. Other activities which
are not listed in Construction Methodologies shall be treated based on the weightage
given by the Project QC Head.

Before carrying out any construction activities at project, testing facilities for the raw
materials shall be established at site as a part of quality check. Materials used in the
construction activities shall be tested in accordance with the standard procedures.
Project QC Head shall also be responsible in setting up of the field laboratory for
testing of materials, apart from carrying out various quality checks based on
Construction Methodologies. Only calibrated lab instruments shall be used to carry
out various test as per the standards / procedures and the outputs shall be recorded
as per the WEL standard formats attached herewith in Annexure.

Project Inspection & Test Plan has been established and required to be followed.
Refer to relevant ITP for various activities.

10.2 The type of inspection and QC checks to be carried out for different areas of
construction are as mentioned below:

10.2.1 General Quality related aspects:

 Setting up field laboratory to carry out laboratory testing
 Conducting laboratory test for raw materials as specified in ITP.
 Inspection of temporary work, concrete batching plant, hot mix plant, crushing
plant etc.
 Material testing and approval
 Mix Designs approval
 Shuttering / formwork Quality
 Alignments, leveling of shuttering
 Checking the foundation levels and co-ordinates.
 Compaction during concreting work

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 Project Quality Plan

 Post construction activities such as appropriate curing, deshuttering / stripping

time etc and identifying the defects if any.

10.2.2 Specific Quality related aspects:

 sp_aspect

The areas listed above and the Quality aspects are not limited and are broadly
mentioned to describe the general inspection and checks to be carried out. Project
Quality Head shall identify the areas/activities specific for any particular project and
shall generate the ITPs for the same. ITP will be prepared describing product
characteristics, controlling specification, verifying document, frequency of
inspection/test and inspection category.

10.3 Construction Methodologies: For main activities, the methodologies are

developed and used. Few are listed below:
S# Name of the Activity
SE
G
_I
SEG_NAME_0
D
_
0
SE
G
_I
SEG_NAME_1
D
_
1
3 SEG_NAME_1
4 SEG_NAME_1
5 Wet Mix Macadam
6 Bituminous Mixes
7 DLC
8 PQC
9 Box culverts
10 SEG_NAME_1
11 Pile foundations
12 Road marking
This above list is indicative and will be revised whenever a new activity is identified
and approved for execution.

10.4 Inspection and Testing:

During the execution of the Activity all the applicable inspection and test
requirements as per contract specifications / good engineering practice and other
relevant applicable codes / standards / specifications etc. is identified in Inspection

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 Project Quality Plan

and Test Plans (ITP) for various sub-activities. Following parameters shall be
considered during the preparation of the ITP:

 The type of equipment, product characteristics, which then determine the

types of measurement as mentioned in engineering spec.

 The location of suitable measurement points in the realization process

sequence.

 Characteristics of the product, equipment to be measured at each point, and

the documentation and acceptance criteria to be used.

 Established points for customer to witness or for verification of selected

characteristics of product as required by the contract technical specifications.

 Inspections and Testing required to be witnessed by Statutory and Regulatory

authorities.

 Where, when and how the PCC intends to engage qualified third parties (if
required) to perform inspections or testing.

The prepared ITP will be attached to the relevant Construction Methodologies along
with necessary inspection and testing formats. No construction function will be
started without approval of the relevant Construction Methodologies and inspection
and test plans by relevant authority of project management function. The ITP will be
reviewed periodically during execution of the activity for effective operation of
various quality assurance and quality control activities. Client if required will
approve ITPs.

10.5 Validation of Process:

Validation of various processes will be done at appropriate stages/as per spec. In

the cases where an item cannot be fully verified through inspection and testing,
validation of process will be carried out. Records of process validation and
revalidation shall be maintained including method, equipment and qualification of
person(s) for performing such process.

10.6 Calibration of Measuring and Monitoring Equipment:

The following steps will be followed for calibration of various measuring and
monitoring equipment at field testing laboratory.

a) Ensure that the adequate care is taken while selecting the measuring and
monitoring equipment with suitable specification, including range to be measured
for the full-scale range of the device, accuracy and robustness, under specified
environmental conditions.
b) Ensures that the initial calibration has been carried out prior to first use, in order to
validate the required accuracy (accuracy and precision). All instruments shall be
calibrated with traceability to National / International Standard.
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 Project Quality Plan

c) Test and verify periodically as specified, where appropriate, the software and
procedure controlling automatic test equipment.
d) The Quality function at site will be responsible for calibrations and will prepare a
calibration plan indicating therein the frequency of calibration, method of
calibration, accuracy required and other details as mentioned in the format.
e) Recall periodically for adjustment, repair and recalibration, keeping in
consideration the following:
i. The manufacturer’s specification
ii. Results of prior calibration
iii. The method and extent of use and
iv. Maintain their required accuracy in use
f) Evidence through a record be kept indicating the identification of the
Instruments, frequency of recalibration, calibration status.
g) Document and maintain records or evidence to indicate the traceability

Standards of known accuracy and stability, preferably to nationally or internationally

recognized standards, and where such standards do not exist, the basis used for
calibration.

h) All persons responsible for measurement / testing using calibrated equipment

shall ensure that the calibration status of the measuring and monitoring devices
are identified through suitable means on the equipment and shall take care to
safeguard the devices against any adjustments that may invalidate the calibration
status.

11.0 HANDING OVER OF WORKS:

Prior to the completion of the project, when substantial completion has taken place
and adequate enough to make the project functionally useful, the project
management, construction management function will start collecting, storing,
updating and retrieving of relevant information of completed works / structures of
the project and ensuring that these information is checked for validity.

The facility will be handed over to the owner in accordance with the contract.

11.1 Tests on Completion

The Tests on Completion will be carried out as per CA

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12.0 CONTROL OF NON-CONFORMING PRODUCT(S) / PROCESS (S):

All project team members are responsible for identifying and reporting any non-
conformity found in process or activities within their area of responsibility. The non-
conformity so found shall be identified by suitable means so as to prevent its
unintended use or delivery.

Action to be initiated for all Internal / External NCR’s within 7 days from the date of
issue. Monthly summary statement to be provided with explanation of aging NCR’s
not closed. Repetition of same or similar non conformity shall be strongly
discouraged.

12.1 Responsibilities for Identification of Nonconforming Products:

For Identification of Product Non conformities:

 All concerned Process User’s / and site Quality department personnel during
execution / inspection.

 For initiation and implementation of Corrective / Preventive Actions:

 All concerned Process User’s / HOD’s at HO and Projects.

 For Disposition of Product Non conformities after verification of corrective

action:

 Site Quality department personnel.

12.2 Identification, Review & Reporting of Product Non conformities:

1) Whenever nonconformity is found or identified, the concerned person informs

his/her immediate superior about the observation.

2) The superior will inform the Head - Quality Department.

3) Upon information/ or observation during inspection about Product Non

conformity, concerned member of the Quality department will further verify the
discrepancy or Non-Conformity and its existence. If the Non-Conformity exists
then a Non-Conformance report will be made and issued to concerned product
user and subsequently the concerned departmental head will be informed about
the existence of Product Non conformity to initiate further action(s).

4) Non conformance report will consist of the following information about the
observed Product Non conformity:

a. Non conformity report no., date:

b. Non conformity issued to department:
c. Identification of Non conformity:
d. Description of Non conformity:
e. Classification of NCR: Minor / Major
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 Project Quality Plan

f. Disposition of NCR: Repair/Rework/Reject/Use as is

g. Proposed Corrective / or Preventive Action(s): by HOD
responsible for delivery of product.
h. Target date for completion of Corrective/Preventive action(s)
i. Verification status of Remedial/Corrective/Preventive
action(s): by
QM personnel
j. Close out status of Non conformity.

12.3 Disposition:

Type of Disposition will be decided as per the following:

Repair:
If the Structure, material can be used after repair, which will not affect the final
product as specified in the customer requirement, then repair will be done. If the
activity being executed is unsafe to persons working on that activity and the activity
which will result in to deviation of established Environment management practice,
then the necessary remedial action will be taken to prevent harm to environment /
human beings. The approval for such repair action will be taken from the concerned
Authority. The repair action will include appropriate inspection and testing to verify
the conformance of the product after the repair.

Rework:
If a rework is needed to overcome the Non-Conformity then it will be done as per
the approved procedure. This rework will be re-inspected and tested so as to
confirm that Non-Conformity does not exist and the final product is as per the
customer’s specified requirement.

Reject:
If the Non-Conforming structure, equipment, material or activity cannot be made fit
for the process then it will be rejected. If a material, equipment or activity is found
Non-Conforming at receipt, it will be returned to the manufacturer, supplier or
originator. And the Non-Conformance report will be submitted along with a claim
statement for new equipment, material or document.

Use as is:
In cases of Minor Non- conformities where the Non-Conforming product can be
used for the process, which will not deviate from the customer’s specified
requirement at final stage then no action will be taken and the process will continue.
This concession will be authorized.

12.4 Implementation of Corrective action, Closure of NC’s:

The Corrective and Preventive action will be implemented to eliminate the cause of
existing or potential Non-Conformities in order to prevent their recurrence.

12.4.1 Initiation of Corrective Action(s):

Corrective action(s) will be initiated and implemented by concerned process user’s
as per the agreed relevant corrective/preventive action(s) and it will be ensured that
the relevant actions have been implemented by agreed date of completion. Process
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 Project Quality Plan

user will inform to relevant Quality Team member after completion of agreed
Corrective actions.

12.4.2 Closure of a Nonconformance:

The concerned site Quality department personnel will ensure that the
recommended corrective/preventive actions are undertaken, implemented and
verified. After verification of effectiveness of remedial/corrective or/preventive
action(s) the Non-Conformities will be closed by site Quality department.

Summary of Non conformities will be maintained and sent to Quality Head- H.O.
every month for further analysis and action.

The flow chart depicted in the subsequent page outline the established
Nonconformity control system.

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 Project Quality Plan

R e s p o n s ib ilit y

P ro d u c t u s e r N o n - - C o n f o r m i t y Id e n d it ie d
Q M P e rs o n n e l

P ro d u c t u s e r P r e v e n t e d f r o m u n in t e n d e d
u s e / d e liv e r y

P ro d u c t U s e r Is s u e o f N o n - - c o n f o r m it y N o n -C o n fo rm a n c e
Q M P e rs o n n e l R e p o rt R e p o rt

H O D /P r o d u c t u s e r T a k e r e m e d i a l a c t io n
( C o r r e c t io n )

H O D /P ro d u c t u s e r / R e v ie w o f N C f o r p r o p o s in g
Q M P e rs o n n e l C A /P A

Im p le m e n t a t io n o f C A / P A
H O D /P ro d u c t u s e r w it h in a g r e e d d a t e

Is t h e C A / P A No
Q M P e rs o n n e l v e r if ie d a n d In f o r m t o H O D
f o u n d e f f e c t iv e ?

Yes

Q M P e rs o n n e l C lo s e t h e N C

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 Project Quality Plan

13.0 TRAINING:
Training and Evaluation of all Project involved personnel including workmen in a
continuing process to determine the necessary work competence of people to
perform the work effectively and efficiently, Identification of necessary Training needs
and imparting training.

14.0 DISTRIBUTION LIST:

This document will be distributed as per the following distribution list:
S# Department Designation Location
1 Client --- Site
2 Operation Project Manager Site
3 Highway Manager Site
4 Structure Manager Site
3 Quality Manager Site

15.0 LIST OF ATTACHMENTS:

Annexure details Title of Attachment No. of Pages
Annex 1 ITP 10 No.
Nos.
Nos.

ATTACHMENTS
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 Project Quality Plan

Annex 1

Frequencies Criterion for Tests of Material & Works

Inspection Frequency of MoRTH ref. / Inspec. Category

Sl. Controlling Verifying
and Testing Inspection / Acceptance WAS Engineer/ Record Remarks
No. Specification Document
Description Testing criteria PL Client

A EARTHWORK (Ref. MoRTH 5th Revision Section 305 & 900)

903.2.1 &
Gradation/Si IS:2720 (Part- 2 tests / 3000 305.2.1.4; D:<75
i ILR P WR
eve Analysis 4) m3 mm(Embk.)/<50
mm (Subgrade)

Liquid Limit
IS:2720 (Part- 2 tests / 3000 903.2.1, 305.2.1.1
ii & Plasticity ILR P WR
5) m3 LL<50&PI<25
Index

903.2.1 &
Max. Dry
IS:2720 (Part- 2 tests / 3000 305.2.1.5; Table
iii Density & ILR P WR
8) m3 300-1
OMC

Deleterious IS:2720 (Part- As and when

iv ELR 903.2.1 P RR
Content 27) required
Test
903.2.1 & results
Moisture IS :2720 1 test / 1500
v ILR 305.3.5.2; -2% to P WR
Content (Part-2) m3
+1% of OMC
1 test / 3000 903.2.1; Min % as
IS:2720 (Part-
vi CBR ILR m3 for per design P WR
16)
Subgrade requirement
Free Swell IS:2720 (Part- 1 test / 3000
vii ILR 305.2.1.2; < 50% P WR
Index 40) m3
Field Density
Compaction
IS:2720 (Part- 1 Set of test / 903.2.2 & Table
viii for ILR P WR
28) 3000 m2 300-2
Embankmen
t
Field Density
Compaction
IS:2720 (Part- 1 Set of test / 903.2.2 & Table
ix for ILR P WR
28) 2000 m2 300-2
Subgrade/S
houlder
Field Density
IS:2720 (Part- 1 Set of test / 903.2.2 & table
x Compaction ILR P WR
28) 3000 m2 300-2
for OGL  
B GSB (Ref. MoRTH 5th Revision Section 401 & 900)
Test  
IS:2720 (Part- results
Gradation/Si 4) & As per table 900 -
i ILR 1 test / 400 m3 P WR
eve Analysis IS: 2386 3 & Table 400-1
(Part-1)
ii Liquid Limit IS:2720 (Part- ILR 1 test / 400 m3 As per table 900-3 P WR
& Plasticity 5) & 400-2; LL<25%
Index PI < 6%

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 Project Quality Plan

As per table 900-3

Moisture IS :2720
iii ILR 1 test / 400 m3 & 401.3.2; -2% to P WR
Content (Part-2)
+1% of OMC
As per table 900-3
Field Density IS:2720 (Part- 1 set of test /
iv ILR & 401.3.2; >98% P WR
Compaction 28) 1000 m2
of MDD
Deleterious IS:2720 (Part- As and when
v ELR As per table 900-3 P RR
Content 27) required
As per table 900-3
IS:2720 (Part- As and when
vi CBR ILR , Table 400-2; P WR
5) required
>30
Max. Dry
IS:2720 (Part- As and when
vii Density & ILR Cl no 401.3.2 P WR
8) required
OMC
Water IS:2386 (Part- 401.2.2, Table
Initially on
viii Absorption/ 3)/IS:5640/IS ILR 400-2; < 2/ wet P WR
submission
Wet AIV test 2386 (Part-4) AIV <40.
Liquid Limit
and IS:2720 (Part- As and when Table 400-2; LL<
ix. ILR P WR
Plasticity 5) required 25, PI<6
Index
C WMM (Ref. MoRTH 5th Revision Section 406 & 900)
Aggregate
Impact
900-3 & Table
Value/ Los IS:2386 (Part- 1 test / 1000
i ILR 400-12; AIV<30%, P WR
Angeles 4) /IS5640 m3
LAA<40%
Abrasion
Value
Gradation/Si IS: 2386 900-3; As per
ii ILR 1 test / 200 m3 P WR
eve Analysis (Part-1) table 400-13
Flakiness
Index & IS:2386 (Part- 900-3 & Table
iii ILR 1 test / 500 m3 P WR
Elongation 1) 400-12; <35% Test
Index results
Atterberg IS:2720 (Part- 900-3 & 406.2.1.2;
iv ILR 1 test / 200 m3 P WR
Limits 5) PI<6
Field Density IS:2720 (Part- 1 set of test / 900-3 & 406.3.5;
v ILR P WR
Compaction 28) 1000 m2 >98% of MDD
Max. Dry
IS:2720 (Part- As and when
vi Density & ILR Cl no 406.3.5 P WR
8) required
OMC
406.2.1.1; < 2%, if
Water IS:2386 (Part- Initially on >2% soundness
vii ILR P WR
Absorption 3) submission test to be carried
out.  
D BITUMINOUS COURSES

1 PRIME COAT / TACK COAT (Ref. MoRTH 5 th Revision Section 502, 503 & 900)
Table 900-4, 502
& 503; Bitumen
Quality of
i IS:8887 ILR / MTC 1 test/lot Emulsion P WR/RR
binder
complying with IS
8887
Temperature
900-4 & 503.4.3; Test
of Binder for At regular
ii   ILR 20 to 70o C for P WR results
application close interval
Emulsion
of tackcoat
900-4; As per
Rate of
Three tests MoRTH Table
iii spread of   ILR P WR
per day No . 500-3 and
Binder
500-5  

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2 DBM / BC (Ref. MoRTH 5th revision section 507 & 509)

900-4, 505.2.1 &
504.2.1 and Table
Quality of
i IS: 73 ILR/ MTC 1 test/lot 500-1 Bitumen P/R WR/RR
binder
complying with IS
73
Aggregate 900-4,Table 500-
Impact IS:2386 (Part- 8 & 500-16; AIV
Value / Los 4) & DBM <27% BC<
ii ILR 1 test / 350 m3 P WR
Angles IS: 2386 24%
Abrasion (Part-3) LAAV DBM <35%
Value BC <30%
Flakiness
Index & IS:2386 (Part- 900-4, 500-8 &
iii ILR 1 test / 350 m3 P WR
Elongation 1) 500-16; < 35 %
Index
One test per
source and 900-4, 500-8 &
Stripping
iv IS:6241 ILR whenever 500-16; Coating P WR
value
source will retained>95 %
change
One test per
Water source and 900-4, 500-8 &
IS:2386 (Part-
v absorption of ILR whenever 500-16; < 2 % for P WR
3)
aggregate source will DBM & BC
change
One test per 900-4, 500-8 &
Soundness
source and 500-16; Sodium
(Magnesium IS:2386 (Part-
vi ELR whenever Sulphate <12% P/R RR
and sodium 5)
source will Magnesium
sulphate)
change Sulphate <18%
One test per
Sand source and
IS:2720 (Part- 900-4, 505.2.3, Test
vii equivalent ELR whenever P/R RR
37) >50 results
test source will
change
One test per
source and 900-4, 505.2.3;
Plasticity IS:2720 (Part-
viii ILR whenever <4% (passing P WR
Index 5)
source will 0.425mm sieve)
change
For each 400
MT of mix
900-4, As per
IS 2386 (Part- subject to a
ix Mix grading ILR table 500-10 , P WR
1) minimum of
500-13 of MoRTH
two tests per
plant per day.
For each 400
MT of mix
produced, a
set of 3
Asphalt Marshall
Institute specimens to
Manual MS-2, be prepared
AASHTO and tested for 900-4, 500-11,
Stability of
x T245, ASTM ILR stability, flow 500-12 & Cl.no P WR
mix
D 2041, IS value, density 505.3.1
6241, and void
AASHTO T content subject
283 to a minimum
of two sets
being tested
per plant per
day.
Water AASHTO T One test per 900-4, Table 500-
xi ELR R RR
sensitivity of 283 source and 8 & Table 500-16;  
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 Project Quality Plan

>80% , is only
mix
whenever required if the
(Retained
source will minimum coating
tensile
change retained less than
strength)
95%
One test for
Control of each 400
binder Asphalt tones of mix
900-4, Table 500-
xii content and Institute ILR subject to a P WR
13 &500-18
grading of Manual MS-2 minimum of
the mix. two tests per
day per plant.
Density of 900-4, 505.3.5 &
xiii compacted - ILR 1 test / 700 m2 507.3.5. >=92% of P W
layer GMM
900-4 and Table
500-16; Min 55 for
Polished BS-812 (Part-
xiv ELR 1 test / source BC. ( For DBM R RR
Stone Value 14)
this test not
required)  
Rate of th
After every 5
XV spread of ILR 900-4
truck load
mix material
Test
Temperature
results
of binder in
boiler,
aggregate in
At regular
XVI dryer and ILR 900-4
intervals
mix at the
time of
laying and
compaction
Table: 500-8 &
Grain Size
XVI IS 2386 (Part- As and When 500-16, Max 5%
Analysis of ILR
I 1) Required passing 0.075mm
Aggregates
sieve
3 MODIFIED BINDER (Ref. MoRTH Section 501.2.1, 900)
Softening 1 test / source
i IS:1205 ILR / MTC P/R WR/RR
point and 1test / lot
1 test / source
ii Penetration IS : 1203 ILR / MTC P/R WR/RR
and 1test / lot
Elastic IRC SP : 53 1 test / source
iii ILR / MTC P/R WR/RR
Recovery Appendix -2 and 1test / lot 900-4; As per IS Test
5642 results
v Flash point IS:1209 ILR / MTC 1 test / source P/R WR/RR
Seperation
difference in IRC SP : 53
vii ILR / MTC 1 test / source P/R WR/RR
softening Appendix -2
point  
E MATERIAL FOR STRUCTURES

1 COARSE AGGREGATE (MoRTH Section 1007)

IS:383,
Specific
i IS:2386 - Part ILR 1 test / source 1007 P WR
Gravity
III
Weekly once
Gradation/Si IS:383,IS:238 As per table 1000-
ii ILR (or) as and P WR
eve Analysis 6 – Part 1 1
when required Test
Aggregate 1007; AIV <45% results
Impact for concrete other
IS:383, 1) One per
Value / Los than for wearing
iii IS:2386 Part ILR source P WR
Angles surfaces; <24%
IV 2) Weekly
Abrasion for wearing
Value surfaces. Los  
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 Project Quality Plan

Angles Abrasion
value <50% for
Concrete other
than for wearing
surfaces; <30%
Max. for wearing
surfaces.
1) One per
Flakiness IS:383,IS:238 MoRTH clause
iv ILR source 2) P WR
Index 6 P-1 No. 1007; < 35%
Monthly
Specific
Gravity and
IS383,IS:238
v Water ILR 1 test / source - P WR
6 P-III
absorption of
Aggregate
Soundness
Sodium sulphate
(Magnesium IS:383,IS:238
vi ELR 1 test / source <12% Magnesium R RR
and sodium 6 P-V
sulphate <18%
sulphate)
Alkali-
IS:383,IS:238 Fig. 6 of IS:2386
vii Aggregate ELR 1 test / source R RR
6 P-VII Part VII
reactivity
IS:383, ASTM
Petrographic As per IS: 2386
viii 295, IS:2386 ELR 1 test / source R RR
Analysis Part VIII
Part VIII

Table 1 of IS:383-
Deleterious IS:383,
ix ELR 1 test / source 1970 (Max. 5% for R RR
Material IS:2386 P-II
total constituents)
2 FINE AGGREGATE (MoRTH section 1008)
Silt/Clay IS:383,IS238 1008 & IS 383;
i ILR Weekly once P WR
Content 6 Part II <3%
IS:383,
Specific
ii IS:2386 Part- ILR 1 test / source - P WR
Gravity
III
Gradation/Si
1008; As per table
eve IS:383, Weekly once
1000-2, Fineness
iii Analysis, IS:2386 Part ILR (or) as and P WR
Modulus: 2.0 <
Fineness III when required
FM < 3.5
Modulus
Water
IS:383,IS:238
iv absorption of ILR 1 test / source 1008; <2% P WR Test
6 P-III
Aggregate results
1008; Table1 of
IS383,
Deleterious IS:383 Max. 5%
v IS:2386 Part ELR 1 test / source R RR
Material for total
II
constituents
Alkali-
IS:383,IS:238
vi Aggregate ELR 1 test / source - R RR
6 P-VII
reactivity
Soundness
1008; Sodium
(Magnesium IS:383,IS:238
vii ELR 1 test / source sulphate <10% R RR
and Sodium 6 P-V
MgSO4 <15%
Sulphate)  
3 ORDINARY PORTLAND CEMENT (Ref. IS: 269 & MoRTH section 1006)
Standard
1006 & IS 8112 /
i Consistency ILR / MTC P/R WR/RR
One test for 12269
(%) Physical
Initial Setting each
properties 1006; Min 30 Test
ii Time ILR / MTC Consignment P/R WR/RR
(As per IS: minutes results
(Minutes) (or) as and
4031)
when required
Final Setting 1006; Max 600
iii ILR / MTC P/R WR/RR
Time minutes
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 Project Quality Plan

(Minutes)
Fineness 1006; Min 225
iv MTC R RR
(m2/Kg) m²/Kg
Soundness
v MTC 1006; Max 10 mm R RR
test
Compressiv 1006; IS 8112 / IS
vi ILR / MTC P/R WR/RR
e Strength 12269
Chloride Chemical
vii R RR
content properties each 1006; IS 8112 / IS
MTC
Chemical (As per IS: Consignment 12269
viii 4032) R RR
Composition
4 WATER (MoRTH section 1010)
To
Neutralise
MoRTH 1010;
100ml
Should not require
sample of
i IS:3025-22 more than 5ml of R RR
water, using
0.02 normal
Phenolpthal
NaOH
ein as an
indicator
To
Neutralise MoRTH 1010;
100ml One per Should not require
ii sample of IS:3025-33 source for more than 25 ml R RR
water, using approval and of 0.02 normal
mixed H2SO4 Test
ELR there after
indicator results
quarterly as
SC 4 of MoRTH 1010;
iii Organic IS:3025-18 R RR
contract 200mg/lit
MoRTH 1010;
iv Inorganic IS:3025-18 R RR
3000mg/lit
Sulphates MoRTH 1010;
v IS:3025-28 R RR
(SO4) 400mg/lit
Chlorides MoRTH 1010;
vi IS:3025-32 R RR
(CI) 500mg/lit
Suspended MoRTH 1010;
vii IS:3025-17 R RR
matter 2000mg/lit
MoRTH 1010;
viii pH R RR
>6.0  
5 ADMIXTURE (MoRTH section 1012)
Chloride IS:9103,
i ELR / MTC As per MoRTH R RR Credentia
Content IS:6925
Cl:1012.2 along ls / MTC /
Dry Material MTC for each List of
ii IS:9103 ELR / MTC with IS:9103:1999 R RR
content supply and Projects
with Amendment Test
one 3rd party used,
iii Ash content IS:9103 ELR / MTC No. 1 of January R RR results
test for each shall be
2003 and
source submitted
Amenment No. 2
Relative for
iv IS:9103 ELR / MTC of August 2007. R RR
density approval.
6 CONCRETE (MoRTH section 1700)
i Sample of IS 1199 ILR Every concrete 1717.6 Table P WR Test  
cube (A spread over 1700-9; Qty. of results
sample entire period of concrete (Cu.M) -
means a set concreting No. of samples:
of 3 cubes) (1-5) - 1, (6-15) -
2, (16-30) - 3, (31-
50) -4,
(51&above) -
4+One additional
for each 50Cu.M
or part thereof
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 Project Quality Plan

1704.1; As
Every batch of specified for
concrete at specific Grade,
Workability IS:1199,IS:45
ii ILR dispatch as structural P WR
(Slump) 6, IRC:21
well as delivery component and
point method of
concreting
1717.7.1; (i)
Mean strength
from any group of
four consecutive
samples should
Cube be greater than
As per
iii Strength of IS : 516 ILR Characteristic P WR
requirement
Concrete strength
(ii) Individual
sample not less
than
Characteristic str
– 3 MPa
F NP4 HUME PIPES (MoRTH section 2900)
Cube
ELR S/ As per
i Strength of IS :516 P WRS/RR
MTC requirement
Concrete
Dimensions,
ELRS / As per
ii Workmanshi IS : 458 -2003 2900; Testing of P WRS/RR
MTC requirement
p & Finish NP4 pipes shall be Test
IS : 458 as per IS 458 & IS results
Hydrostatic ELRS / 2% of the
iii -2003, 3597 P WRS/RR
test pressure MTC pipes
IS:3597
IS : 458
Three edge ELRS / As per
iv -2003, P WRS/RR
Bearing test MTC requirement
IS:3597  
G REINFORCEMENT STEEL(MoRTH section1009)
Diameter,
i
Unit weight
Ultimate
ii Tensile
Strength
Yield
iii
strength
Bend & For each
iv 1009.3; As per IS : R RR Test
Rebend IS: 432 / 1786 MTC consignment
1786 report
Percentage
v
of elongation

Chemical
vi
Composition

H REINFORCED EARTH WALL (MoRTH Cl:3100)

i Reinforcing - ELR / MTC One per As per BS 8006 R RR Test  
material source and other relevant results
Metallic ones, ASTM,
Strip/Geotex Section 3102 of
tile/ Geogrid MORT&H
type Specifications as
relevant to
particular type of
material

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 Project Quality Plan

Angle of
3103; not less
ii interface - ELR 1 test / source R RR
than 30 degree
friction  
3103; Not more
than 15% of the
IS 2720 One sample
iii Grading ILR particles shall P WR
PART 4 per 1500m3
pass 75 micron
sieve  
J MASTIC ASPHALT (MoRTH Cl:516)
As per Table 500-
39 of MORT&H
One sample
i Binder IS 73 ILR/MTC Specifications for P/R WR/RR
per Lot
Road and Bridge
Works
Powder passing
the 75 micron
Filler sieve and having
One per
ii (Limestone IS:1514 ELR calcium R RR
source
powder) carbonate content
not less than 80%
Test
by weight.
results
One test per
As per MoRTH T
Mix each 400
MoRTH T- table No. 500-40,
proportions tonnes of mix
iii 40.500-41; ILR 500-41 based on P WR
and binder subject to a
500-42 thickness of the
content min. of two
mastic asphalt.
tests per day
516.3.2; 50 to 70
without coarse
Hardness Two tests per
iv IS 1195 ILR/ELR aggregate & 10 to P/R WR/RR
number day
20 with coarse
aggregate.  
K MARKING & OTHER ROAD APPURTENANCES

1 HOT APPLIED THERMOPLASTIC ROAD MARKING MATERIAL (Ref. MoRTH Section 803.4.)
803.4.1.2; White : Test  
Day light results
luminance at 45
degrees –65
percent min. as
AASHTO M per AASHTO
i Luminance MTC 1 test / source R RR
249 M249 Yellow: Day
light luminance at
45 degrees- 45
percent min. as
per AASHTO
M249
803.4.1.2; When
applied at a
temperature
specified by the
manufacturer and
AASHTO T
ii Drying Time MTC 1 test / source to the required R RR
250
thickness, the
material shall set
to bear traffic in
not more than 15
minutes.
803.4.1.2; Not
Skid
iii BS 6044 MTC 1 test / source less than 45 as R RR
Resistance
per BS 6044.
iv Cracking   MTC 1 test / source 803.4.1.2; The R RR
resistance at material shall
low show no cracks on
temperature application to
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 Project Quality Plan

concrete blocks.
803.4.1.2; 102.5
Softening
v ASTM D 36 MTC 1 test / source + 9.5°C as per R RR
Point
ASTMD 36.
803.4.1.2; Not
Flow AASHTO M more than 25
vi MTC 1 test / source R RR
Resistance 249 percent as per
AASHTO M249
Yellowness
803.4.1.2; Not
Index (for
AASHTO M more than 0.12 as
vii white MTC 1 test / source R RR
249 per AASHTO M
thermoplasti
249
c paint)
803.4.2.3; As per
MoRTH
viii Glass Beeds MTC 1 test / source Table 800-10 of R RR
803.4.2
MoRTH Specs.
2 METAL BEAM CRASH BARRIER (Ref. MoRTH Section 811)
811.3.1.2; W
beam, steel beam
Post & Spacer –
IS:5986/8500/AST
M/A-570
Physical
i - MTC 1 test / source Dome/Hex head R RR
Test
bolts-IS:1367 and
IS:1364 Anchor
Bolts-
IS:2062/ASTM-
A36
The dimension Test
shall be as per results
drawings. The
posts shall be
vertical with a
tolerance not
Dimension / For every
ii - ILR / MTC exceeding 6 mm R WR/RR
Tolerance supply
in a length of 3m.
The barrier will be
erected true to the
line and grade as
per MoRTH
Section-811.3.6  
3 ROAD DELINEATORS (Ref. MoRTH Section 806)
Once per As per MoRTH
i Physical - MTC R RR
source Section 806
Dimension For every As per MoRTH Test
ii - ILR / MTC P/R WR/RR
Test supply Section 806 results
For every As per MoRTH
iii Installation - Visual P W
installation Section 806  
4 HECTOMETER / KILOMETER / BOUNDARY STONES
One per As per MoRTH
i Material - Visual P WR
source Section 807
For every As per MoRTH
ii Dimension - ILR supply/ Section 801 and P WR Test
installation 802 results  
5 TRAFFIC SIGNS / OVERHEAD SIGNS
As per MoRTH
One per
i Material - ELR / MTC Section 801 and R RR
source
802
For every As per MoRTH
ILR / ELR /
ii Dimension - supply/ Section 801 & P/R WR/RR Test
MTC
installation 802 results  
L BEARINGS-POT & PTFE
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 Project Quality Plan

Properties of Inspection &

i P/R WR/RR
the material MoRTH ILR / MTC testing for MoRTH clause
Test
clause 2006 each lot at 2006 & IRC 83
Tests for results
ii & IRC 83 vendors part III P/R WR/RR
acceptance
ILR / MTC premises  

Legend:- WR- 10% Witness, WRS-10% witness at supplier source, P-Performance, R-Review, RR- Review of Reports, ILR-Internal
Lab Report, ELR- External Lab Report, MTC-Manfacturer's Test Certificate, D- Size of the boulder, SC- Special Conditions of Contract

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Project Quality Plan

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