P
ROVINCIAL RECONSTRUCTION,
REHABILITATION
& SETTLEMENT AUTHORITY
[Draft] Quality Assurance
& Quality Control Manual
PROVINCIAL DISASTER MANAGEMENT AUTHORITY, Government
of Khyber Pakhtunkhwa
November 2021
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
1 | Page
Abbreviations & Acronym
ACI
American Concrete Institute
ASCE
American Society of Civil Engineer
ASTM American Society for Testing and Materials
BOQ
Bill of Quantities
C&W
Communication & Works
CBR California Bearing Ratio
IBC
International Building Code
KPRP
Khyber Pakhtunkhwa Reconstruction Program
NFPA
National Fire Protection Association Code
PHED
Public Health Engineering Department
PM
Project Manager
QA
Quality Assurance
QC Quality Control
QCM
Quality Control Management
QS
Quality System
SOW Scope of work
TS
Technical Specifications
UFAS
Uniform Federal Accessibility Standards
USAID
United States Agency for International Development
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Reconstruction Program
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Contents
Introduction .................................................................................................................. 4
Section 1: Definitions ................................................................................................... 6
Section 2: Introduction of QA/QC Manual .................................................................. 7
Section 3: Objectives of QA/QC Manual ..................................................................... 8
Section 4: Communication Plan for Construction Site ................................................ 9
Section 5: Duties, Responsibilities, and Authority of QC Personnel ........................ 10
5.1 KPRP/Client’s Engineer ............................................................................... 10
5.2 Consultant Engineer .................................................................................... 10
5.3 Contractor’s Project Manager ..................................................................... 10
5.4 Contractor’s Engineer(s) ............................................................................. 11
Section 6: Design Stage of Infrastructure Project ...................................................... 12
6.1 Background .................................................................................................. 12
6.2 Purposes of Design Quality Control Plan ................................................... 12
6.3 Conditions of Design Quality Control ........................................................ 12
6.4 Components of Design Quality ................................................................... 12
6.4.1 Proper Team ............................................................................................... 12
6.5 Key Steps in Achieving Desired Quality ...................................................... 13
6.5.1 Client Needs Assessment ........................................................................... 13
6.6 Design Quality Control Methodology ......................................................... 13
Section 7: Construction of Infrastructure Work ....................................................... 15
7.1 Contractor’s Submittals Procedures ........................................................... 15
7.2 Changes in Approved Submittals ................................................................. 16
7.2.1 Supplemental Submittals........................................................................... 16
7.2.2 Engineering Review .................................................................................. 16
Section 8: Laboratory Testing for Construction Materials ........................................ 12
8.1 Testing Plan and Logs .................................................................................. 12
8.2 List of Construction Materials for Testing .................................................. 12
8.3 Construction Materials Method of Testing and Frequency ......................... 13
Section 9: Complete Rework Items Procedures ....................................................... 17
9.1 Responsibility ............................................................................................... 17
9.2 Item List for Rework ................................................................................... 17
9.3 Rework Procedure for Construction Work ............................................... 17
Section 10: Reporting for Construction Works ........................................................ 19
10.1 Daily Inspection Report ............................................................................... 19
10.2 Monthly Progress Report ............................................................................ 19
10.3 Materials Testing Record............................................................................. 19
10.4 Site Document Control............................................................................... 19
10.5 Quality Records .......................................................................................... 19
10.6 Documentation Storage .............................................................................. 20
Section 11: Annexes ................................................................................................... 21
Annex 1: Daily Progress Report ........................................................................... 22
Annex 2: Weekly Progress Report ...................................................................... 24
Annex 3: Request for Testing (RFT) .................................................................... 27
Annex 4: Request for Survey (RFS) ...................................................................... 30
Annex 5: Request for Inspection (RFIP) ............................................................... 33
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Annex 6: Nonconformance Report .................................................................... 33
Annex 7: Request for Audit Testing ..................................................................... 36
Annex 8: Request for Audit Survey (RFS) ............................................................ 39
Annex 9: Request for Information ...................................................................... 41
Annex 10: Design Checklist ............................................................................... 43
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Introduction
a) Khyber Pakhtunkhwa Reconstruction Program (KPRP)
The USAID funded Khyber Pakhtunkhwa (KP) Reconstruction Program supports the KP
Government's efforts to rebuild public infrastructure destroyed during the 2009 military
operations and the 2010 flooding. The Program rebuilds education, health, water, sanitation,
and irrigation facilities. It is also working closely with the KP Government to improve its
capacity to deliver essential services.
Objectives
The Program's objectives are to rebuild conflict-affected public schools, health and water
infrastructure; improve the learning environment in public schools by providing essential
furniture and laboratory equipment; and to rehabilitate essential irrigation and communication
infrastructure damaged by the 2010 flash floods.
Main Activities
Reconstruct and rehabilitate militancy affected public schools
Rehabilitate and improve outdated water systems
Rehabilitate and restore flood-damaged infrastructure
Provide essential equipment to damaged health facilities, and furniture and lab
equipment to schools
Provide consultative services to improve the capacity of the KP government to
manage reconstruction programs
b) Quality Assurance and Quality Control function in KPRP/PaRRSA
The quality assurance (QA)/ quality control (QC) function in KPRP is a robust mechanism
encompassing different layers of site monitoring to ensure that quality of construction is in
accordance with the specifications and other contractual quality parameters. QC mechanism
comprises of site engineers of contractor and consultant companies, respectively. While the
QA mechanism comprises of designated engineers of Executing Agencies (i.e., C&W, PHED
etc.) and KPRP/PaRRSA. Please refer to the following graphic for the details of QA and QC
mechanism of KPRP/PaRRSA for construction related activities:
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Organogram of QA/QC functions
KPRP/ PaRRSA
(Client)
Deputy Director
(Engineering)
Consultant
company
Site Engineer
Contractor
Project Manager
Site Engineers
Executing Agency
(Line departments
e.g., C&W, PHED)
Engineer
Engineers
Quality Assurance (QA)
Quality Control (QC)
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Section 1: Definitions
Quality is a desirable characteristic (based on the expectations set by all stakeholders) in
construction. At its core, quality in construction means that a construction project is
completed within the defined guidelines set out in the Scope of Work (SOW). SOW serves
as a set of rules for the project based on the client’s expectations, and sheds light on how
to execute the project in a way that meets these standards.
Quality Assurance (QA): is a set of planned and systematic actions which are laid out
before and after a construction project starts. This is an additional layer of quality review
(in addition to the QC cycle) to provide adequate confidence that the construction work
satisfies quality requirements.
Quality Control (QC): The operational techniques and activities (such as reviewing,
checking, inspecting, testing, etc.) that are used to fulfill requirements for quality in
construction works. In simple words QC is the process of inspecting the construction site
to identify and correct defects.
Quality System (QS): A set of documented processes that seeks to provide confidence
that the project outputs will fulfill the functional requirements. The Quality System should
enclose the organization, responsibilities, human resources, materials, equipment,
processes, inspections, testing, and other parameters of subproject. A key element of QS is
the QA / QC Manual.
Deficiency: This shall be any deviation from the plan or specification that results in lower
quality of work, reduces useful life circle of work and impairs functionality of work and
unsafe condition, or materials change in the appearance than is deemed by the Site Engineer
to be unsatisfactory and to require fulfillment according to the contract, technical
specifications and Bill of Quantities (BOQ).
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Section 2: Introduction of QA/QC Manual
Successful execution of construction projects is dependent on quality control, which
is essential to the
construction of infrastructure projects. Deficiencies in constructed
facilities can result in huge cost
overruns and lead to delays of the construction
schedule. Even with minor deficiencies, reconstruction
may be required, which causes
delays. In the worst case, failures may cause
personal injuries or fatalities. Sound
project management supported by a thorough
quality control system (QCS) ensures
that the construction work is executed professionally with value engineering.
For
efficiency of the quality control mechanism, it is mandatory to have a fair and
transparent mechanism with clear communication and instructions on construction site.
The quality system described in this manual shall form the basic activities and
processes to be utilized to monitor and control throughout the success of any
construction project.
The quality control plan requires the engineer to:
Maintain sufficient inspection system and perform inspections that will
ensure
compliance with agreed specifications.
Maintain inspection records and make them available to KPRP.
Allow KPRP to conduct its own tests and inspections.
Make follow ups on tests and inspections for its benefit to the project
deliverables. The
quality control obligations in the testing and inspection remain
independent and unchanged.
Assist KPRP in ensuring completion of the project within the approved
timeline,
budget, and quality.
Provide quality design management and construction management services that
consistently meet KPRP statutory and regulatory requirements.
Be responsive in executing good engineering practices to eliminate potential
quality
defects.
Continuously improve all functions within the project team in collaboration with
the client through innovation and creativity.
Ensure to rectify deficiencies and to prevent future defects.
Define and share the acceptance criteria for any construction project.
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Section 3: Objectives of QA/QC Manual
The main objective of quality control is to ensure that the under-construction facility is
achieving the approved standards and agreed specifications. With a clear and brief
quality system each member of the construction supervision team can ensure that it
has played its part in the success and value of the construction project. Procedures that
have been strictly followed will make sure that KPRP is receiving a cost-effective quality
construction in a timely manner.
It is essential that the quality system is evaluated regularly in order to revise
procedures as and when required. Suggestions for improvements in procedure
changes and revisions from all parties
involved in the program are necessary.
This quality control plan does not endeavor to repeat or summarize
agreement/contract requirements. It
describes the process and procedures that the
consultants’ engineers will use to ensure compliance with those requirements. The
agreement/contract is the foundation for the outcomes expected from the quality
control plan.
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Section 4: Communication Plan for Construction Site
A formal communication chain is the foundation of a successful construction project.
All team members should have a point of contact.
In order to have clear communication between KPRP, line department, consultant and
contractor
,
engineers of the parties involve shall have the following responsibilities:
All construction documents like approved drawings, BOQ’s, specifications,
submittals, test reports,
inspection reports, daily/ weekly /monthly reports, safety
reports shall be available, maintained and stored in Site Engineer office for review.
Engineers shall be available on construction site and perform inspections during
construction on daily basis.
Consultant’s engineer shall continuously coordinate/liaise with the client and
contractor during pre
construction (site preparations), construction, and post
construction project cycle.
Consultant’s engineer shall carry out routine joint inspections with client, site
engineer to document the actual status of the project to
ensure that work activities
at site have been done in accordance with the signed contract. Agreement on
observations shall be noted and entered in separate daily inspection reports.
Client engineer shall ensure that the quality control is applied in accordance
with quality control
procedures.
Client engineer shall conduct inspection independently with contractor’s
representative and write
notification in daily inspection report.
Client and site engineer shall reach consensus on methods of inspection and testing
according to the
specifications in accordance with QA/QC Manual.
Client and consultants’ site engineers shall agree on the size of the construction task
and the required materials for the tasks require to be
tested in accordance with
the technical specifications and QA/QC. Follow up joint witness inspections
at the
test laboratory by client and site engineer is mandatory.
Client and Site Engineer shall reach consensus on defect rectification requirements
which shall be noted in separate defects log/reports.
Client and site engineer shall be bound to rectify all such defects and to notify the
contractor to take
immediate action in accordance with “Rework” section of this
Manual.
In case of any differences on defects between client and consultant site engineer,
the matter will be forwarded to the KPRP head office for further expertise.
Client and site engineer shall update their QC and QA reports on daily basis and
old issues shall not be
repeated after rectifications measures are taken and closed.
Client and site engineer shall conduct weekly QC meetings on site. Minutes of
the meetings have to be
prepared by site engineer.
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Section 5: Duties, Responsibilities, and Authority of
QC Personnel
5.1 KPRP/Client’s Engineer
The client's engineer role is very important to the overall success of construction project.
They play an active role in approving project plans, requesting changes, raising issues and
risks, approving milestones, releasing payments, and accepting (or declining) the final
deliverables of the project.
The client engineer is responsible and accountable for the execution of
all activities
from the start to the end of the project. The client shall facilitate the efforts of the
design and construction projects.
5.2 Consultant Engineer
The role of consultant engineer is supervision and monitoring of the site to assure the
construction quality control system.
Site engineer shall report directly on daily basis
regarding the progress of the construction works. Site
engineer’s quality control team
ensures that the program quality management and safety systems are
being implemented
according to the requirements of the client. The site engineer oversees all technical
aspects in the specified technical area of the work including but not limited to
assessment, design, Bill of
Quantities (BOQ) calculations, technical specification,
monitoring and other related tasks.
The site engineer's responsibilities include managing different parts of construction
projects, supervision of his team members, preparing estimates for time and material costs,
completing quality assurance, observing health and safety standards, and compiling reports
for different stakeholders.
The site engineer also supervises contractors site engineers including
contractors QC
engineers. He/she shall provide field project control support by identifying and monitoring
project
related issues. He/she shall directly communicate with contractors and client
when necessary and
directly report to the client for technical advice, support, and field
resolution when necessary. The site
engineer shall supervise all technical aspects of
infrastructure project implementation work in the specified
technical area of work
including but not limited to assessment, design, Bill of Quantities (BOQ),
calculation,
technical specification, and monitoring of work. The site engineer shall be responsible for
the
design integrity, professional design standards and all services required by the
agreement.
In addition to
implementation and management of the quality control
program, the site engineer is required to perform submittal review and approval, make
sure testing is performed and provide QC certification and documentation as required in
the agreement.
5.3 Contractor’s Project Manager
A Project Manager oversees the planning and delivery of construction projects to ensure
the work is completed as per agreed specifications, on time and within budget. With so
many facets to consider in both pre- and post-construction, the Project Manager works
closely with engineers, architects and more to drive the best outcome.
In the approved contract agreement, the contactor is bound to assign a Project Manager
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with required qualifications and skills to ensure the completion of the infrastructure project
according to the approved construction schedule The Project Manager shall ensure that
Quality Control Management (QCM) standards are executed, and the QC certifications
and documentation are prepared as required under the agreement.
The Project Manager shall be on the construction site during any shifts when construction
work is in progress.
5.4 Contractor’s Engineer(s)
The role of contractor site engineers is to supervise all construction activities of site and
shall assist the Project Manager in processing and maintaining files for submittals, reports,
and meeting minutes. The site engineer shall be responsible for:
To ensure the quality and quantity of the work based on the design and technical
specifications.
Manage all processes on site and be responsible for the material planning and timely
provision, the planning of work force to ensure the project implementation in time.
The site engineer is empowered by the Project Manager to suspend construction activities
while defects are corrected after informing the client’s representative. There shall be at
least one site engineer present per site.
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Section 6: Design Stage of Infrastructure Project
6.1 Background
Considering the limited resources, and the social and economic conditions and
aiming to produce and achieve the highest yield, quality control and quality assurance
are gaining
considerably large importance.
6.2 Purposes of Design Quality Control Plan
The purpose of the design quality control plan is to:
Align the project outputs as per Client’s needs
Decrease the design and development cost in terms of time and money
Maximize the use of local construction materials like sand, stone, bricks, etc.
Maximize the use of local menpower (skilled and un-skilled labor)
Achieve the maximum possible yield from available resources
6.3 Conditions of Design Quality Control
The safety, durability, comfort, and aesthetical requirements of universally accepted
standards and codes such as ASCE, IBC or equivalent are fulfilled technology proposed
should be applied in the location technology proposed is tutorial and educative to local
people.
6.4 Components of Design Quality
6.4.1 Proper Team
The consultant responsible for design QC shall provide or recruit trained professionals
who have experience in developing designs. All matters concerning the
quality control of
the project shall be reported in writing to the client and site engineer.
6.4.2 Proper Utilities
The consultant shall provide proper equipment and dependable software for analysis,
design, and computer aided drawings.
6.4.3 Adequate Training
The consultant engineer who will have contributions to the designs shall be
trained about
internationally accepted codes designs techniques and construction systems.
6.4.4 Codes and Standards
Conformation of the designs to the following codes and standards will be achieved by:
Training of team
Spontaneous checks during all phases of design
By preparation of code conformation reports at the milestones of the design schedule
6.4.5 Governing Codes of Quality Control
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IBC, International Building Code
ACI, American Concrete Institute Code
NFPA, National Fire Protection Association Code
UFAS, Uniform Federal Accessibility Standards
ADA, Standards of Accessibility Design, Department of Justice
ASTM, ACI Construction Standard Index
6.5 Key Steps in Achieving Desired Quality
6.5.1 Client Needs Assessment
Clear understanding of the requirements of the Client
Developing and proposing a satisfactory architectural preliminary design that satisfies
the above-mentioned code requirements
Documentation of geographic and climatic requirements
Documentation of cost efficiency requirements
Presentation of the above to the Client together with code analysis report.
Obtaining approval of the Client
6.5.2 Design Criteria and Construction Materials
Selection of design criteria for construction project, selection of materials of
construction, technologies.
Reporting to the Client together with possible alternatives.
Obtaining final approval of the Client for design and construction materials
Finalizing architectural designs according to comments of the Client and
Consultant’s Site Engineer
Obtaining approval of the client for architectural designs
6.5.3 Finalizing Drawings, BOQ and Technical Specifications
Developing structural, mechanical, electrical designs considering the seismic,
dynamic, live load evaluations, permissible or ultimate stresses, alternate loadings
possible, heat and electric energy requirements, applicable codes and technologies.
Presenting and reporting the designs and calculations to the Client, accompanied by
code analysis.
Preparing quantitative calculations for tendering (BOQ)
Preparing Technical Specifications (TS) to achieve desired quality and to enable the
bidders to submit the correct cost estimation to avoid future disputes
obtaining approval of the client
6.6 Design Quality Control Methodology
The following steps shall be followed while designing any construction activity:
A network that is accessible to all designers shall be established and all daily works
shall be stored to a
common area in this network at the end of each working day.
Architects and Engineers shall proceed according to the items listed in the
checklists as presented on
Annexes-10 and at the start of each activity shall
prepare a list of particulars of the requirement (e.g.
main requirement of client or
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task, codes to be followed, minimum or maximum size requirements etc.).
The Engineer of Record shall examine the report, shall invite the other engineers
or architects for their
comments if the task requires additional information from
different disciplines etc. and shall approve the report together with his/her additional
comments.
After achieving the mentioned approval, the designer shall proceed. The designer
shall provide a code
confirmation list as soon as he completes the design.
The design team shall have one quality control meeting every week to discuss the
parts of the
designs that were produced in the preceding week. All comments shall
be recorded, and minutes be provided to the Client and site Engineer.
After completion of a specific design the design team will make a final review of
the work and check whether it fulfills all the requirements of the Client, checklists
of this QC plan, and the codes.
A spreadsheet highlighting the changes shall be
made accordingly.
Any field design changes will be brought to the knowledge of the Client and Site
Engineer so that the reasons of the request are clearly understood and
negotiated. If required, the client shall be informed about the design changes
accompanying a report explaining the
reasons, effects on the project and financial
requirements.
After approval of the request by the Client, the designs shall be revised and
submitted to the client for the
final approval.
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Section 7: Construction of Infrastructure Work
7.1 Contractor’s Submittals Procedures
In construction, submittals are a contractor’s proof of complying with construction
documents or a permitted plan set. These include shop drawings, specifications, technical
data, and samples for items such as steel, bricks, sanatory fitting etc.
Consultant’s Site Engineer shall manage and control the processing of contractors’
submittals. After being reviewed
for completeness, submittal documents shall be passed
on to the relevant staff in consultant design team for review and verification for
compliance with the requirements of contract. Submittal documents need to be
approved
finally by the Client.
The detailed progress schedule shall be submitted within 14 days after the award of the
contract
and may be updated as required or as per request by the contractor. If
any changes apply, the
contractor shall get it approved by the Client.
Site Engineer shall maintain a completed submittal schedule and a list of products for
all items requiring
Client’s review and approval, as follows:
Submittals, including description of the item and the name of the manufacturer,
trade name, and model number
Specification and BOQ reference
Intended submission/resubmission date(s)
Lead time to delivery/anticipated delivery date(s)
Highlight any items that require expedited review to meet the project schedule
Identify which submittals require Client’s and/or Site Engineer’s approval
These schedules shall be presented in the prescribed form in both electronic and hard
copy versions and
shall be updated and sent to the Client and/or Site Engineer on a
monthly basis.
7.1.1 Review Period
Contractor shall ensure that submittals are prepared in advance to enable the Client
(in coordination with site engineer) to conduct a review and accord approval before
commencement of
the
related work. The contractor is responsible for the preparation
of submittals according to the time
schedule to avoid delays. If any delays occur due
to contractor’s default, penalties shall be applied according to the
terms of
contract.
7.1.2 Submittal Reviewers
The Contractor shall submit all the required submittal forms in paper as well as
in electronic form to the Site Engineer.
Site Engineer shall review the submittal documents and assess whether the
package is complete. If submittal is incomplete the submittal shall be returned to
the contractor.
The complete submittal documents (along with all the attachments) shall be
stored in client engineers’ database and shall be forwarded to the relevant
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reviewer of the consultant’s design department.
The consultant design team shall review the submittal documents and ensure
that the submittal is in compliance with the contract specifications and will
accord its approval if the submittal documents were in agreement the
specifications. However, in the consultant will require explanations then the
consultant will return to the Site Engineer with comments.
Site Engineer, in consultation with the client, shall re-submit the submittal to the
contractor with his/her determination.
The contractor’s Project Manager and/or site engineers and design engineers
shall be authorized to review and certify submittals prior to its submission to the
consultant Site Engineer. The Client shall accord the final approval after the
submittal is approved by the Consultant.
7.2 Changes in Approved Submittals
Changes in approved submittals shall not be allowed unless these approved submittals
with changes have
been resubmitted and approved as prescribed in section 7.1.
7.2.1 Supplemental Submittals
Supplemental submittals initiated by the contractors for consideration of corrective
procedures shall
contain sufficient data for review. Supplemental submittals shall be
made in the same manner as initial submittals.
7.2.2 Engineering Review
Submittals shall be reviewed for conformance with the TS, BOQ and the contract
agreement.
Review actions shall have the following meanings:
Approved: is an acceptance
Submittal appears to conform to the respective requirements of the
specifications and
agreement
Disapproved: is a nonacceptance
Means that the submittal is deficient to the degree that the reviewer cannot
make a thorough
review of the submittal
The submittal needs revision and is to be corrected and resubmitted.
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Section 8: Laboratory Testing for Construction
Materials
Construction materials testing involves the essential examination of all structural
materials used in the construction of a project. Materials testing helps us to quantify
and understand whether a material or product is suitable to a certain
application. Materials testing points us to limits of a material to handle a load or an
operating condition. Materials that have not been tested and directly used in a product
can be extremely dangerous. The data collected during testing and the final test results
can be very useful to engineers and designers.
If required, the Client and Site Engineer reserves the right to require the
contractor to conduct materials
testing through approved laboratories for onsite
and off-site testing. The selected laboratory for
each location needs to be approved by
the Client and Site Engineer.
8.1 Testing Plan and Logs
A testing plan is a detailed document that describes the testing strategy, objectives,
schedule, estimation, deliverables, and resources required to perform testing of a
construction work. Testing Plan helps to determine the efforts needed to validate the
quality of the materials being tested.
When the tests are performed, the Contractor’s Project Manager or site engineer shall
record on theTesting Plan and Log”
the date the test was performed and the date the
test results were sent to the Site Engineer. The
site engineer shall submit all test results
to the Client.
If necessary, materials qualification testing shall be done before commencement of
construction activity to verify that the materials
comply with the requirements of the
contract, the technical specifications and BOQ. The
contractor shall obtain
representative samples of the materials designated as the proposed source of the
materials. Test samples shall be sent by the contractor to the approved testing
laboratories. The testing
laboratory shall report all test results for determination of
materials quality.
The Client shall periodically inspect the material being used. If determined that the
characteristics of the
material being used differ from the material initially tested or
designed, the contractor shall repeat the
qualification testing. If the new material
qualification test results meet the criteria of the technical
specification as determined,
the materials may be used for the work, otherwise, previously approved
materials
shall be used or other acceptable materials shall be sampled and tested as noted above.
8.2 List of Construction Materials for Testing
Following is the list of materials which are essential to be tested before and during
construction of project. The client and site engineer reserve the right to require testing of
materials in addition to the materials as stated below:
Cement
Sand
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Crush
Bricks
Asphalt
Mortar
Aggregates
Concrete
Reinforcement steel
Wires
Plaster
Electrical Material
Plumbing Material
Sanitary Material
Guard Rails
Signs
PPE
Wood
Shuttering Material
Other as necessary (refer to technical specification, BOQ, and technical drawings
recommendations)
8.3 Construction Materials Method of Testing and Frequency
All quality assurance testing shall be conducted in line with project specifications,
the contract, technical specifications, BOQ and individual project construction
plan.
The Site Engineer shall observe all relevant testing methods, as previously identified.
The
documentation and reporting of test results shall be included with the daily
construction quality control report and
entered QC system.
All test results shall be updated, filed separately and be presented to the Client. All
tests shall be carried out in accordance with international codes and/or
specifications.
The table below shall be adjusted according to the project specifications and
required standards
in the design:
Required Test Test Method Test Frequency Acceptance Criteria (Verified
by consultant
Engineer )
Grading & leveling
As per IBC 1803 Land surveying Prior to start excavation To establish finish floor
elevation
as per
specifications and
drawings
Compaction
CBR Test
Modified
Proctor
compaction test
ASTM D 1883 &
ASTM D1557
One sample of material
delivered 5
samples of
compacted material for each
400m2
Ensure compact fill to
95% or higher grade of
maximum density and
layers of 20cm.
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Required Test Test Method Test Frequency Acceptance Criteria
Verified by Consultant
Engineer)
Concrete
Compressive Strength ASTM C39 Preliminary testing of mix
design (Test at first 7 day and
28 days). Samples of strength
test will be
taken not less
than once (Five samples) for
every 100 m3, or less than
once for each 465 m2, nor
less than once a day. 3
cylinders @ 7days, 3
cylinders @ 28days and 2
cylinders reserve
Minimum strength
based on
technical
requirements and
structural design
Water/Cement Ratio
Preliminary testing of mix
Di
Limit .45 by weight
Slump Test ASTM C143 1 per batch prior to pouring
concrete
Reinforced concrete
100mm Non reinforced
concrete, side
Reinforcement Steel
Minimum Yield Strength ACI 318 Section
3.5
On delivery on site samples
will be
taken from every type
of rebar prior to installation
and suppliers’ certificate
Must meet specifications
requirement of grade 60,
> / 420
MPa yield strength
Water
Clearness & Cleanness ACI 318 Sec.3.4 Prior to concrete mix Insure free of oil, acids,
salts,
organic and other
substances
Aggregate Concrete
Gradation, salt, harmful
materials
As per 318 Sec. 3.3
ASTM C33 &
C330
One sample at source prior to
commencement of work
Insure physical
requirement of coarse &
fine aggregate. Absence of
harmful substances
Grout
Minimum Compressive
Strength
ASTM C1019 Preliminary testing of mix
design. Test once on a daily
basis during grouting
operations.
(i) Compressive strength
for MTC project remain at
least 13.8
MPa) @ 28 days
Compressive strength
at least 3000 psi (21
MPa) @ 28 days
Cement Mortar
Type M and / or S
Cement
ASTM C 270
08a
Building Code
Requirements for
Masonry
Structures
Table
2.2.3.2, Table
3.1.8.2, Table
5.4.2
Masonry cement mortar
(pre
packaged).
Mix Ratio:
Correct proportion of sand &
water
to meet ACI 530.08 min.
required strength.
Ref. Mix Ratio for Type M & S
(refer:
QC/SITE/7)
Type M: Compressive Strength
(
17.2 MPa) 2500 PSI @ 28
days.
(ii) Type S: Compressive
Strength 1800 psi (12.4
MPa) @ 28 days
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
15 | Page
Required Test Test Method Test Frequency Acceptance Criteria
Verified by Consultant
Engineer)
Masonry Block
Compressive
strength &
dimensions
Sampled and
tested in
accordance with
ASTM C 140
Preliminary test of 3 samples
of concrete blocks delivered on
site
Unit conforms to ASTM
C90. ASTM do not require
design
standard. Only help
assure compliance with the
design.
Compressive strength and
not
less than of 1500 psi
Ceramic Tiles
Inspect Appearance
and dimensions of
tiles
As per
manufacturer’s
approved
specifications
Samples to be submitted for
approval
Conform to the
requirement of ANSI
A137.1.& Specifications
Carpet
Adhesive as per
ASTM D 6004
As per
manufacturer’s
approved
specifications
Samples to be submitted for
approval
Ensure compliance with
approved sample and
adhesive
Linoleum Flooring & Vinyl Flooring
Thickness,
resistance
chemicals, heat
light,
flexibility,
static load
ASTM F2034 Provide sample of Linoleum
and adhesive for approval
Ensure approved materials,
self-leveling cement used as
per specs.
Insulation
Thickness, thermal
conductivity,
compressive
strength,
water
absorption
ASTM C115397
ASTM D3564
Sample upon delivery Insure 5cm thick, thermal
conductivity .032, strength
120
pa as per specs.
Bituminous Roofing Membrane & Roof Insulation
Tensile strength,
rapture strength
Roof Insulation
system / product
ASTM C 57801
(Extruded,
expanded rigi
d
thermal
properties
Prior to application
Ensure tensile strength
600N/5cm, rapture
strength130N/5cm, as per
specifications
Structural Steel Roof
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
16 | Page
Required Test Test Method Test Frequency Acceptance Criteria
Verified by Consultant
Engineer)
Welding
Reqr: welding
rod ,
Heater’s inspection
materials, Dye
Penetrant,
magnetic
flux
Inspection
according to
AWS D1.1 and
IBC 1704
AWS D 1.1 & 1.8
Inspection continuous onsite
and shop
Ensure welding is in
compliance with AWS
D1.1, workmanship,
technique, qualification of
welders
Electrical wires & Cables
Manufacturer’s
certificate
Inspection
Electrical QC/
Design
Engineers
and
NEC standards
Samples to submitted prior to
installation
To be approved by QC
electrical
Engineer
Plumbing Pipes
Manufacturer’s
certificate
Field Pressure
test and IPC
standards
After installation of plumbing
pipes
According to the
mechanical
specifications
Water Well
Physical,
Chemical &
Bacteriological
Test according
to
WHO
requirements
Well water will be tested after
drilling well
Tested by approved
water testing lab.
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
17 | Page
Section 9: Complete Rework Items Procedures
Any sign of system deficiencies whether discovered by the Client, Site Engineer and/or
the Contractor/Designer, shall result in modifications to the system to correct these
defects.
The contractor shall be informed by the Site Engineer in writing when a defect is
identified and shall
immediately stop work or use of the defective materials. The
contractor shall repair /replace or correct deficiency
before work commences.
If the contractor believes a suitable repair is possible, executed at their expenses, the
Contractor has to
prepare a plan to affect repair or correction and submit to the Client
and Site Engineer for approval.
9.1 Responsibility
It is the responsibility of the Site Engineer to ensure that identified construction
defects are corrected in a
timely manner. Defects identified by the client shall also be
noted and rectified in a timely
manner.
9.2 Item List for Rework
The Site Engineer shall maintain a list of works that do not comply with the
construction plans, technical specifications, contract and BOQ. The list shall have the
following details:
Identification, what items need to be reworked
The date the defect was originally discovered
The date the item was corrected
An item that is corrected on the same day it is discovered shall not be reported in this
log, but in the daily
quality control report.
9.3 Rework Procedure for Construction Work
When noncompliances with technical
specifications or drawings are observed in the
executed construction works, materials and installations, the contractors’ project
manager and Site Engineer shall make sure that nonconforming materials, works, or
installations are identified and separately stored to prevent unintended use.
The Site Engineer shall immediately inform the contractor of any non-compliances. After
receipt of such notice, the
contractor shall take corrective actions immediately.
Variations from the contract requirements and/or quality shall be
documented for
corrective actions by the contractor. A nonconformance report shall be issued
to the
contractor for corrective actions to be taken within 3 working days.
If the contractor fails to correct a minor defect after 5 days of the notice, it shall
result in a nonconformance which shall be formally documented.
If the contractor fails to take corrective actions regarding the identified non
conformances within the specified period of
time, a Stop Work Order shall be issued to
the contractor.
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
18 | Page
Related or continuing activities of construction shall be stopped forthwith until the
rectification of deficiencies
that are critical to the integrity of the structure or the facility
and/ or safety of public.
After issuing the Stop Work Order, the site engineer shall inform the client to
help
resolve the issues with contractors’ management.
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
19 | Page
Section 10: Reporting for Construction Works
10.1 Daily Inspection Report
Daily inspection reports shall be prepared by consultant’s site engineer to document
complete details of the day-to-day progress on site.
The Site Engineer shall inspect contractor’s daily construction work, efficiency of
deployed manpower, tools,
and equipment, start and stop times, and QC inspections of
work activities.
The Site Engineer shall review, comment, and approve the daily reports presented by the
contractor. Reports shall include pertinent information including problems encountered
during construction, work progress, safety hazards encountered, instructions given, and
corrective actions taken, delays encounters, a record of visitors to the work site, quality
control problem areas, weather conditions, photographs, deviations from the QC plan,
construction deficiencies encountered, and record of meetings held.
10.2 Monthly Progress Report
The monthly progress reports shall contain overall progress of project activities
reported for the
current month including financial progress, milestones, key dates,
accomplishments, bottlenecks, materials
certification, tests performed, and QC
deficiencies corrected.
10.3 Materials Testing Record
Results of materials testing are also important record to be maintained at construction
site as a proof of construction quality. Test results of all the construction materials are
recorded in the record book maintained on the construction site to improve the quality
of work.
All testing activities shall be recorded on the relevant construction QC Report,
indicating the name and
number of tests performed, specification paragraph reference,
and location performed. It shall be
entered into computerized QC tracking system.
10.4 Site Document Control
Document controllers shall maintain project documents. These documents ensure that
accurate information is distributed throughout the organization, on time, to the people
who need it.
The Document Controller (Administration support staff) shall implement the project
quality system to
control the identification, numbering, modification, approval,
distribution and filing of all documents,
data and drawings.
The checking, approval, identification and distribution of the document and drawings are
as indicated in
the Project Quality System Procedure (PQSP). Each document shall be
assigned a unique number in
accordance with standard numbering procedures.
10.5 Quality Records
The quality records to be maintained and kept for the program are as follows:
Inspection Records
Method Statements
Non-conformances and corrective reports
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
20 | Page
QC plan and audit reports
Test records, certificates, warranties, and guarantee
Client, contractor, and consultant progress reports
Contractor and consultant monthly payment reports
Incoming and outgoing correspondence
Technical drawings, shop drawing and as-build drawings
Document register log
Design documents
Tender documents
Construction records
Other related records
10.6 Documentation Storage
QC team shall maintain all construction related documents and submittals in a
combination
of a secure edocument filing and storage system. The computerized
document control tracking system
shall be archived in consultant’s network server.
Internal project QC audit shall be conducted at a random interval on
the document
controls system when necessary.
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
21 | Page
Section 11: Annexes
Annex 1: Daily Progress Report
Annex 2: Weekly Progress Report
Annex 3: Request for Testing (RFT)
Annex 4: Request for Survey (RFS)
Annex 5: Request for Inspection (RFIP)
Annex 6: Nonconformance Report
Annex 7: Request for Audit Testing
Annex 8: Request for Audit Survey (RFS)
Annex 9: Request for Information
Annex 10: Design Checklist
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
22 | Page
Annex 1: Daily Progress Report
DPR Date
Site No.
Project Title
Location
Province
Coordinates
Contractor
Date of Contract Signature
Date of Construction Start
Date of Completion (Contract)
New Completion Date
(Time
Amendment)
Percentage of Project Complete
Is project on schedule Y/N
Weather/
precipitation
Temp.
day
(°C)
Temp.
night
(°C)
Work on Stop
If “YES”, short explanation
Reported by
1.
Personnel on Site:
Contractor
Super
visor
Enginee
r
Fore
man
Skilled
Labor
Unskille
d
Labor
Operators
Others
2.
Major equipment/machinery on site:
Type:
Number
Acceptable Quality: Y/N
Remarks
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
23 | Page
3.
Supplied Material:
Type
Quantity
Delivered
Acceptable
Quality Y/N
Total
Quan
tity
Acceptable
Approved
Y/N
Remarks
4.
Work Progress :
Building/
Structure
BoQ No
Work
Description
5.
Inspection & Testing:
Type
Y/N
Forms
Attache
d
Forms
Sent
Separatel
y
Remarks
Material
Test
Routine Inspection
Preparatory
Inspection
Initial Inspection
Follow up
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
22 | Page
6.
Issued documents (RFI, Non Conformity, Non
Compliance etc.) :
Date
No.
Issued
by
Issued to
Description
Date of
rectificat
ion
7.
Instructions to the Contractor:
Occasion
Instructions for rectifying
Date for rectification
8.
Design Issues:
Date
No.
Issued
by
Issued to
Description
Date of
rectificatio
n
9.
QA Report : ( Deficiency Ongoing / completed )
Deficiency
Status
Remarks
10.
Safety Issues:
Attended by
Safety issues discussed
Date for
rectificatio
n
11.
Other Discussions/ Meetings:
With
Discussed
Comments
[Draft] QA/QC Manual Khyber Pakhtunkhwa
Reconstruction Program
(KPRP)
23 | Page
12.
Visitors
Visitor
Reason for visit
Comments
13.
Pictures:
Please insert pictures documenting activities and defects and describe when
necessary, the
number of photos is not limited
Description/ location
Description/ location
P
H
O
T
O
P
H
O
T
O
Description/ location
Description/ location
P
H
O
T
O
P
H
O
T
O
24 | Page
Annex 2: Weekly Progress Report
WPR Date
2014-MM-DD
Report
Period
DD
th
to DD
th
of MM.
YY
Site No.
Project Title
Location
Province
Contractor
Date of Contract Signature
Date of Construction Start
Date of Completion (Contract)
New Completion Date
(Time
Amendment)
Percentage of Project Complete
Is project on schedule?
Weather conditions
(brief description)
Average
Temperature
in
rep.
+5° C/
- C
Work on Stop(Y/N) /
Day
If “Y” brief explanation
Reported by
1.
Labor on site:
Day
2.
Equipment on site:
Day
3.
Issued documents (RFI, Non-Conformity, Non
Compliance etc.) :
Date
No.
Issued
by
Issued
to
Description
Date of
rectification
25 | Page
4.
Instructions:
Occasion
Instructions to contractor/ subcontractor/
supplier
Date of
rectification
5.
Design Issues:
Date
No.
Issued
by
Issued
to
Description
Date of
rectification
6.
Safety and Security Issues:
Attended by
Day
Safety Issues discussed
Date for
rectification
7.
Other Discussions:
With
Day
Discussed
Comments
8.
Visitors:
Visitors
Day
Reason for visit
Comments
26 | Page
9.
Pictures:
Please insert pictures documenting activities and defects and describe when
necessary
(photos have to be compressed) 10-20 photos
Description/ location
Description/ location
P
H
O
T
O
P
H
O
T
O
Description/ location
Description/ location
P
H
O
T
O
P
H
O
T
O
27 | Page
Project
No.:
Project
Name:
Contract
or:
Annex 3: Request for Testing (RFT)
DOCUMENT NO: Rev No:
Request for Testing of the following works:
Embankment (Layer…)
Embankment Top (Layer…) Stone Masonry Work
Base Course (Layer…) Culvert
Structural Concrete Material Source
Others…………………………
Type of Test:
Location: Km
to Km
Test Frequency: Volume/Area/Weight Tested:
No.
tests:
This will be ready for test on: Date: Time:
Contractor’s comment/Description:
Requested by (Contractor):
(day/month/year)
Received by (Contractor):
(day/month/year)
Date:
Date:
28 | Page
Test Result:
Lab No.:
Site Engineer’s Comments:
29 | Page
Material Engineer’s Comments
Approved by: Not
Approved, Re-
submit
Checked By:
(day/month/year)
Approved By:
(day/month/year)
Date:
Date:
30 | Page
Project
No.:
Project
Name:
Contract
or:
Annex 4: Request for Survey (RFS)
DOCUMENT NO: Rev No:
Request for Survey of the following works:
O.G.L
Drainage Structure
Embankment Culvert
Structure
Embankment Top Base
Course
Others……………
Type of Survey Check:
Dimensional Tolerance
□Benchm
ark & stations
Alignment
Topographic pick-up
Volume/Area/Length to be checked:
No. Points:
Location: Km
to Km
Chainage/Station Offset (m)
This will be ready for survey on: Date: Time:
Contractor’s comment/Description:
31 | Page
Requested by (Contractor):
(day/month/year)
Received by (Contractor):
(day/month/year)
Date:
Date:
32 | Page
Survey Engineer’s Comments/Recommendations:
Construction Engineer’s Comments:
Approved by: Not
Approved, Re-
submit
Checked By:
Date:
(day/month/year)
Approved By:
Date:
(day/month/year)
33 | Page
Project
No.:
Project
Name:
Contract
or:
Annex 5: Request for Inspection (RFIP)
DOCUMENT NO: Rev No:
Request for Inspection of the following works:
Embankment (Layer…) Stone Masonry
Work
Embankment Top (Layer…) Culvert
Base Course (Layer…) Material Source
Structural Concrete Others
Type of Inspection:
Location: Km
to Km
Inspection Frequency: Volume/Area/Weight inspected:
No. Inspection:
This will be ready for inspection on: Date: Time:
Contractor’s comment/Description:
Requested by (Contractor): Date:
(day/month/year)
Received by (Contractor): Date:
(day/month/year)
Test Result: Lab No.:
32 | Page
Site Engineer’s Comments:
Materials Engineer’s Comments:
Approved by: Not
Approved, Re-
submit
Checked By: Date:
(day/month/year)
Approved By:
Date:
(day/month/year)
33 | Page
Project
No.:
Project
Name:
Contrac
tor:
Annex 6: Nonconformance Report
DOCUMENT NO: Rev No:
NCR No.:
Rev No:
Date Issued
Issued By:
Page:
1
of
2
Description of Non-Conformance:
(List Specification/Drawings,
Other
attachment)
Effect on Construction Schedule:
34 | Page
Proposed
Disposition/Action to
Resolve:
Accept as is:
Remove and replace:
Repair:
Other (Explain):
Comment
Pre
par
Na
m
Dat
e:
35 | Page
Acknowledgement of receipt by Contractor:
Name: Signature:
Date:
Contractor Proposed Action/Remedial Measure:
Remedial Work will be carried out by the Date:
Contractor’s QC Manager/Representative
Name: Signature:
Date:
Contractor’s Project Manager
Name: Signature:
Date:
PO Approval to Proposed
Action/Remedial Measure:
Approve
Not
Approve
Comment:
PO
Representati
ve:
Name:
Signature: Date:
Confirmation/Inspection of
Action/Remedial Measure:
Approve
Not
Approve
Comment:
PO
Representati
ve:
Name:
Signature: Date:
Non-Conformance
Close-Out:
Re-
issued
Close-Out
PO
Representative:
Name:
PO Representative: Verification Non-Conformance Close-Out:
Name: Signature:
Date:
36 | Page
Project
No.:
Project
Name:
Contract
or:
Annex 7: Request for Audit Testing
DOCUMENT NO: Rev No:
Request for Audit Test of the following works:
Embankment (Layer…)
Embankment Top (Layer…) Stone Masonry
Work
Base Course (Layer…) Culvert
Structural Concrete Material Source
Others
Type of Test:
Location: Km
to Km
Test Frequency: Volume/Area/Weight Tested: No.
tests:
Chainage/Station
Off
set (m)
Requested by: Date:
(
day/month/year)
Received by:
Date:
(day/month/year)
Test Result: Lab No.:
37 | Page
(Lab) Comments/Recommendations:
38 | Page
Engineer’s Comments:
Approved by: Not
Approved, Re-
submit
Checked By:
Date: (day/month/year)
Approved By:
Date: (day/month/year)
39 | Page
Project
No.:
Project
Name:
Contract
or:
Annex 8: Request for Audit Survey (RFS)
DOCUMENT NO: Rev No:
Request for Survey of the following works:
O.G.L Base Course
Embankment Drainage Structure
Embankment Top Bridge Structure
Others……………
Type of Survey Check:
Dimensional Tolerance
Benchmark & Stations
Alignment
Topographic pick-up
Volume/Area/Length to be checked: No. Points:
Location: Km to Km
Chainage
Offset (m)
Requested by: Date:
(day/month/year)
Received by:
Date:
(day/month/year)
Survey Engineer’s Comments/Recommendations:
40 | Page
Engineer’s Comments:
Approved by: Not
Approved, Re-submit
Checked By: Date:
(day/month/year)
Approved By: Date:
(day/month/year)
41 | Page
Project
No.:
Project
Name:
Contrac
tor:
Annex 9: Request for Information
Project Code / Location:
RFI No.:
Project Manager:
Report Date:
Site QC Engineer:
Response
Status: / /
Date By:
Documents Ref:
Division:
Area of Concern:
Subject Matter:
(i) Issues:
(ii) Impact:
(iii) Recommendations by
Proposed Solution / follow up Action:
Submitted By: Signature : Date:
Issue closed/open
By:
Date:
Changes :
1.Design
2.Construction
3.Cost Impact
4.Extension of
Yes
No
Signed by:
Site Engineer: Date:
(day/month/year)
Client representative: Date:
42 | Page
Attachments: - (Photos, sketches etc.)
43 | Page
Project
No.:
Project
Name:
Contract
or:
Annex 10: Design Checklist
44 | Page
Date
Project Title
Province
Specific Location
Client
ARCHITECTURAL REVIEW
Yes No Remarks
Have all previous design comments been answered?
Do the drawings comply with the BoQ?
Do the drawings comply with the technical specifications?
Have the designs been coordinated with Structural
Ei ?
Have the designs been coordinated with Electrical
Ei ?
Have the designs been coordinated with Mechanical
Ei ?
Are title blocks labeled correctly?
Are relevant calculations submitted?
Are the drawings updated on the drawing register?
PO PM Signature Date
STRUCTURAL REVIEW
Yes No Remarks
Have all previous design comments been answered?
Do the drawings comply with the BOQ?
Do the drawings comply with the technical specifications?
Have the designs been coordinated with Architects?
Have the designs been coordinated with Electrical
Ei ?
Have the designs been coordinated with Mechanical
Ei ?
Are title blocks labeled correctly?
Are relevant calculations submitted?
Are the drawings updated on the drawing register?
PO
PM
Signature Date
MECHANICAL REVIEW
Yes No Remarks
Have all previous design comments been answered?
Do the drawings comply with the BOQ?
Do the drawings comply with the technical specifications?
Have the designs been coordinated with Architects?
45 | Page
Have the designs been coordinated with Structural
Ei ?
Have the designs been coordinated with Electrical
Ei ?
Are title blocks labeled correctly?
Are relevant calculations submitted?
Are the drawings updated on the drawing register?
P
O
P
M
Signatur
e
Date
ELECTRICAL REVIEW
Yes
No
Remark
Have all previous design comments been answered?
Do the drawings comply with the BOQ?
Do the drawings comply with the technical specifications?
Have the designs been coordinated with Architects?
Have the designs been coordinated with Structural
Ei ?
Have the designs been coordinated with Mechanical
Ei ?
Are title blocks labeled correctly?
Are relevant calculations submitted?
Are the drawings updated on the drawing register?
P
O
P
M
Signature Date
BILL OF QUANTITY REVIEW
Yes No
Remark
Have all previous review comments been answered?
Does the BOQ comply with the drawings?
Does the BOQ comply with the technical specifications?
Has a spell check been carried out?
Are the titles of the BOQ correct?
Are the drawings updated on the drawing register?
P
O
P
M
Signature Date
PO COMMENTS ATTACHED Signature Date
YES
NO
Submitted by
Signature
Date
46 | Page
Reviewed by
Approved by