Site Quality Observation Report #3 Tabuk-J&P

CUSTODIAN OF TWO HOLY MOSQUES KAP 2
SITE QUALITY OBSERVATION REPORT

Doc. No.: NKYSA-KAP2-E1-QAC-QOR-03
Date: 01-02.11.2016
TABLE OF CONTENT
1. INTRODUCTION TO THE REPORT AND PLAN/PROGRAM BEFORE THE SITE VISIT Page 3
2. SITE FINDINGS , DEFECTS , POSSIBLE CAUSE OF DEFECTS,OBSERVATIONS AND RECOMMENDATIONS Page 3
3. REQUIREMENTS AND ACTUAL CONDITIONS Page 9
4. CONCLUSIONS AND RECOMMENDATIONS Page 13
Page 2 of 15
NKY Architects & Engineers

Grand Tower, 11-16 Floors – King Fahd Street, Riyadh, Kingdom of Saudi Arabia
E-mail:info@nky.com.sa CR No: 1010403256
1. INTRODUCTION TO THE REPORT AND PLAN/PROGRAM BEFORE THE SITE VISIT
SQO Report No. : NKYSA-KAP2-E1-QAC-QOR-003 (2016) Site Visit Date : 01-02/11/2016
: Abdul Rahim Abdul Baseeth
: Overview and Analysing of Civil site works (QA/QC Specialist)
Purpose of visit Reviewers Burc Gunvar
in KAP2-E1 project Sites 19-21H
(QA/QC Specialist)
Visited
Contractor : J&P : 19-21H
Project Site(s)
Reference Codes/Docs. : Relevant ACI,ANSI,ASTM,AIEE,ASME,TCA,BS, BS EN,AWI(Architectural Woodwork Institute),NWMA
(National Woodwork Manufacturers Association) documents, relevant clauses of Saudi Building Code,
UBC, International Building Code, International Residential Code, International Mechanical Codes,
International Electrical Code, NFPA, KAP2 Specification for Civil, Architectural, Electrical, Mechanical and
Plumbing Works, Approved Mix Designs, Approved Method Statements, Manufacturer
Recommendations/Instructions, Laboratory Management Plan, frequency of concrete material testing,
MS for Concrete Repair works and approval of repair materials
2. SITE FINDINGS , DEFECTS , POSSIBLE CAUSE OF DEFECTS,OBSERVATIONS AND RECOMMENDATIONS TO
ELEMINATE
# PICTURE OF DEFECTS POSSIBLE CAUSES OBSERVATIONS / COMMENTS
Reinforced Concrete Structural Elements General Recommations
-1- 1. Deformed RCU during 1. Training during tool box talks to

backfilling the employees involved at
1.1 Lack of supervision regarding concrete pouring activity
to concrete quality on site and 2. Taking into account of design
casting operation mix as per Project specification
1.2 Unqualified and unexperienced
3. ASTM and ACI codes and
Laborer.
standards, and structural
1.3 Lack of Training regarding to
design drawing.
concrete casting (MS and orher
trainings) 4. Closing of all gaps/holes of
formworks with foam and tape
to avoid seepage of cement
2.1 slurry
5. Application of approved
concrete repair as per
manufacturing
recommendations
6. Prepare and follow the Method
statements for Cast in Situ
Concrete(include formwork
and rebar works, placing of
concrete, curing),Concrete
Repair, Surveying Works,
Backfill Works
7. Use new and good quality
formwork instead of use old,
damaged and poor quality
Page 3 of 15

formwork. Check the formwork
release agent applications
-2- 2. Deformed RCU during before start to pour and clean
backfilling the formworks just after
2.1 Lack of supervision regarding dismantling of formwork.
to concrete quality on site and 8. Follow the international and
casting operation project spec. requirements for
2.2 Unqualified and unexperienced concrete discharge height in
Laborer. formwork.
2.3 No of QA/QC staff
9. Increase the quality of labor
and staff with trainings.
Costruction,QA/QC staff
2.5 Lack of Training regarding to 10. Increase the Quality Control
concrete casting (MS and orher Staff on sites.
trainings) 11. Increase the control on
Lack of chipping,oiled rebar
batching plant and 3.rd part
laboratory
-3- 3. Concrete Crack 12. Increase the quality awareness
3.1 Lack of supervision regarding of staff with management
to concrete quality on site and review meetings.
casting operation
13. Perform internal audits to see
2.1 3.2 Unqualified and unexperienced
the problems on site and office
Laborer.
(documentation)
3.3 No of QA/QC staff
3.4 Unqualified and unexperienced 14. Start to periodic subcontractor
Costruction,QA/QC staff evaluations and carry on to
3.5 Lack of Training regarding to those evaluations from now on
concrete casting (MS and orher for increase their
trainings) concentration to work.
3.6 Lack of curing activities or 15. Find the root causes of
wrong application. repetitious non-conformances
and prepare a preventive
action plan for prevent the
reoccur of non-conformances
and follow this PAP on site.
16. Regular check on the
dimensions and rigidity of mold
forms before casting
operations.
17. Mould forms conditions will
deteriorate with time and
usage. They should be repaired,
stiffened or replaced when
needed.
18. Appropriate surveying and
levelling equipment should be
used to achieve better
Concrete Crack, top of foundation
alignment.
Page 4 of 15

19. Required alignment and level
should be reconfirmed before
-4-
4. Wrong cutting,installation of casting concrete.
rebars 20. Gradation of coarse and fine
4.1 Lack of supervision regarding aggregates should be tested
to rebar cutting,bending and frequently.
installation operation
21. The cement property changes
should be considered
Laborer.
4.3 No of QA/QC staff 22. The water adjustment should
4.4 Unqualified and unexperienced be done.
Costruction,QA/QC staff 23. There should be a concrete
4.5 Lack of Training regarding to specialist engineer assigned for
Missing Cross-ties, 4 crosstie should be each sites
rabar cutting,bending and
insttaled for 1m2 as per drawings installation (MS and orher 24. All periodic controls shall be
trainings) performed by quality
inspection team.
25. All workers related to concrete
work, rebar fixer, carpenters
and concrete casting teams
2.1
should be monitored closely
and any necessary training
should be done spontaneously.
Any unqualified workers should
be removed from the site.
Page 5 of 15

READY MIX CONCRETE PLANT LAB. 1. Frequency concrete tests are 1. The Mix Designs are used in the
performing with uncalibrated batch plant should be signed
-1-
equipment( except crushing and stamped by contractor’s
mashine).[Picture 1,2,3,4] QA/QC Manager and NKY’s
Area Manager
1.1 Unqualified and Unexperienced
2. Train the engineers about
QA/ QC team.
ready mix concrete plan
1.2 Lack of monitoring and
management requirements
supervision of subcontractor
(can not know the 3. Create a subcontractor
requirements which mentioned monitoring and supervision
in the international standards procedure and follow this
and project specifications for procedure during project. (A
Uncalibrated electronic scales and sieve set ready mix concrete plants ). procedure should be prepared
1.3 Lack of Management. for this issue. This is the one of
1.4 Lack Of Supervision. the ISO 9001 requirements.)
-2-
4. Immediately complete the
calibration of non-calibrated
test equipment.
2.2
Uncalibrated Oven and air meter
-3-
Calibrated crushing machine
Page 6 of 15

-4-
See Page 6
See Page 6
2.2
Bathing Plate Aggregate Weight Scale

Calibration Certificate (there are calibration
certificate for all scales of bathing plant)
J&P SITE LAB.

-5-
2. Positive Observations in General Observations For
Contractor Lab. [Picture Contractor QA/QC activities
5,6,7,8]
1.1 We observed that Contractor
1.1 Contractor’s Management started to improve the Quality
started to consider the Quality Awareness.Still they need to
Issues in Sites. improve their quality
1.2 Effective results of training and awareness and completed
internal audits missing quality requirements
however Contractor is on the
right line.
Calibrated Crushing Machine
Page 7 of 15

-6-
See Page 7 See Page 7
Calibrated Electronic Scales
-7-
See Page 7
See Page 7
2.2
Calibrated Sieve Set and Sand Cone Set
-8-
See Page 7
See Page 7
Lab. General View
Page 8 of 15

3. REQUIREMENTS AND ACTUAL CONDITIONS
# THE REQUIREMENTS INVESTIGATED/ QUESTIONED RESPONSE/ STATUS OBSERVATIONS / COMMENTS
Items has been investigated for the Quality planning and

product / process definitions : OBSERVATION
Contractor have qualified staff to have
-Deployment of approved Method Statements. YES imparted about the work requirements.
-Training and Tool Box talks to the construction teams YES OBSERVATION
including the labours such as; carpenters rebar cutting and We observed that Contractor has a
fixing team, concrete casting team, floor and wall tile team, Training Plan and training has been
plastering team, stair stones application teams and quality conducted as per plan but signatures
inspection team. are missing in training attendance
sheet.
- Is there Any training programs available in the contractor’s YES OBSERVATION

organization? Evidence of Trainers, the groups with the logs We observed that Contractor has a
and attendance. Training Plan and training has been
conducted as per plan.
-Is there any Method Statement available for Concrete Repairs YES OBSERVATION
for various type of defects, which will be observed at site? We observed that Contractor has an
3.1 approved Concrete Repair MS include
various concrete defect.
-Is the NCR logs and NCRs are related with Concreting are YES OBSERVATION
sorted out. Is the closing action performance is good or bad? Contractor has their quality
Check if the main causes and main defects are classified and management system and NCR/SI
grouped. system. Corrective and Preventive
actions are available as a part of NCRs.
We didn’t observed any issued NCR, SI or
similar document. When we asked the
reason, J&P QA/QC team told us ‘ we
didn’t observed any NC in the site,
project site progress at the beginning,
we will issue at the future if they
observe any NC in the site.
-Review the subcontractors list for the site works. (Names/ NO COMMENT
companies/ how many teams and how many skilled labours NO SUBCONTRACTOR DOCUMENT
are available on the site?) PROVIDED BY THE CONTRACTOR
Page 9 of 15

-Preparation and Enabling works before casting concrete starts N/A OBSERVATION
(e.g. Rebar cut & bend, formwork preparation and erection, We didn’t observed any concrete
cleaning and safety of work area. (Find out if the checklists are casting at site but when we inspected
under use?) the ready formwork and rebar which
ready to casting we observed some
defective applications. We observed
that all checklists have been under use
as an attachment of IR.
-Checking the compliance and adequacy of formwork stability, YES (Partially) OBSERVATION
rigidity, tightness and allocation and fixing cover blocks. We observed that formwork and
formwork system acceptable for RCU
stage (foundation and ground beams)
but we will have to observe the
formwork system at future stages.
OBSERVATION
-The quality of cover blocks/spacers are checked if complying N/A We observed concrete covers comply
with the codes requirements with specifications, additionally we
observed that number of installed
concrete cover is not enough, there are
missing concrete covers.
Items has been observed during the investigation of the OBSERVATION

Concrete Production Facilities : For obtain a good quality concrete
bathing plant’s own laboratories should
-Is there any periodic frequent testing on the concrete NO follow international test frequency
ingredient materials? requirement. We observed that Bathing
plans don’t follow the international test
frequency requirement. Such as every
day according they need to follow
material moisture content for modify
mix design according new data what
they get. They need to follow sieve
analysis and many test needed to get
good quality concrete. Additionally we
3.2 observed that bathing plant don’t have
calibration certificate for the
equipment in their laboratory except
crushing machine. Tests, which have
been performed with non-calibrated
equipment, are unacceptable.
NO OBSERVATION
-is the batch plant coordinating/supervising by a specialist We observed that the person who met
material engineer? himself as Lab. Manager share the test
results which has been performed by
their own laboratory. However, he omit
that all test are been done without the-
calibrated testing equipment.
Page 10 of 15

# THE REQUIREMENTS INVESTIGATED/ QUESTIONED RESPONSE/ STATUS OBSERVATIONS / COMMENTS
Items has been observed and analysed at Concrete Casting
areas on the field:
OBSERVATION
-The Survey team control (whether in charge or not) N/A We didn’t observed any concrete
-Checking the related Inspection Requests if including the casting activity on site during site
check lists, drawings, log sheets (for the records) inspection.
-Checked if the examination and testing equipment, tools and N/A OBSERVATION
devices are available or not. We didn’t observed any concrete
casting activity on site during site
inspection therefore we couldn’t found
a chance to check the examination and
testing equipment, tools and devices
using in construction site
-Supporting / temporary equipment such as vibrators, N/A OBSERVATION

compressors, and magnetic cleaning apparatus is adequate or We didn’t observed any concrete
not? casting activity on site during site
inspection therefore we couldn’t found
a chance to check the examination and
testing equipment, tools and devices
using in construction site
3.3
-Checking the Calibrations of all measuring and testing N/A OBSERVATION
equipment is done. We didn’t observed any performing site
test on sites therefore we couldn’t
found a chance to check the
calibrations of equipment which have
been using for site tests.
OBSERVATION
-The type of Formwork material is complies with the YES (Partially) We observed that formwork materials
specification (Only plywood and basic formwork materials) are comply with specifications
additionally we observed that
formwork and formwork system
acceptable for RCU stage (foundation
and ground beams) but we will have to
observe the formwork system at future
stages.
COMMENT
DESIGN, CONSTRUCT, ERECT, SUPPORT,
BRACE, MAINTAIN AND REMOVE
FORMS ACCORDING TO ACI 318, PARTS
1, 2, AND 3 REQUIREMENTS AS WELL AS
Page 11 of 15

ACI 347 REQUIREMENTS FOR LOADS,
LATERAL PRESSURE AND ALLOWABLE
STRESSES; IN ADDITION TO OTHER
DESIGN PARAMETERS SUCH AS WIND
LOADS.
-Casting methods, pouring drop height, vibration use, start to N/A OBSERVATION
end correctly as per ACI’s instruction (layer thickness, the We didn’t observed any concrete
method of pouring from ACI.) casting activity on site during site
inspection.
-Is there any separate Concrete Repair Team available on the NO OBSERVATION
site? We observed that there is not any
active concrete repair team in site
-If yes, are they trained as per approved Method Statement YES OBSERVATION
Specification and Codes/Standards? Contractor has training plan to
following. We observed training data
regarding to different kind of trainings.
-Check if the approval is available for the special purpose N/A

(chemical) concrete repair materials are available on the site.
-Check if the Quality Control team is adequate to cope with NO OBSERVATION

the current work load? Are they qualified well? We observed that there are only two
QC engineer in their organization chart
-Are QC site team authorized for change decisions for the N/A OBSERVATION
necessary modifications? We observed that Project Manager and
Design Team are giving the change
decisions. QA/QC team has no author
about change decisions
-Are there any NCR function initiated and established by the YES (Partially) OBSERVATION
Contractor itself? Any logs available? Contractor has their quality
management system. There are
documents similar with NCR/SI in their
own QMS. Corrective and Preventive
actions are available as a part of NCRs.
We observed there are NCR raised by
Contractor QC team but those NCRs
belongs to Internal Audit of Contractor.
We didn’t observed separated individual
NCR which has been raised by
-Does Contractor has any internal NCR issued about concreting Contractor QC team. Corrective and
or any other items observed in the project? YES (Partially) Preventive actions are available as a part
of Internal Audit NCRs.
-Any Corrective Action or Preventive action records available YES (Partially)

which is issued by the Contractor’s Quality Team?
Page 12 of 15

4. CONCLUSIONS AND RECOMMENDATIONS
4.1 Concrete Production (Batching, Mixing, Transporting and Handling)

1. Batch Plant Manager and operators should be trained about how to modify the concrete mixing as per
the variations encountered on the component material properties and any change on the source of
the materials.
2. Batch Plant manager shall involve the mix trial processes and should control the production in case of
any design changes. All documents and sheets are used on the batch plant shall be signed and
stamped by both parties.
3. Variation in Source of coarse and fine aggregate is continuously take place so minor adjustment in
concrete mix design is required throughout concrete production to maintain concrete quality. Batch
Plant Manager and operators should be trained about how to modify/adjust the concrete mixing as
per the variations encountered on the component material properties and any change on the source
of the materials.
4. All applicable test shall be conducted on fresh and hardened concrete compliance to project testing
frequency requirements.
5. Calibrating Certificates and Calibration Stickers of Batching Plant equipment’s and Batching Plant
laboratory equipment’s shall control periodically with site visits.
6. The trans-mixer which its transportation time (from end of bathing till start of pouring) does not
comply with project specifications shall reject from 3rd Party Lab and Contractor QA/QC team.
4.2 Laboratory Testing

7. Contractor to be sure that approved 3.rd party laboratory and Ready Mix Batching Plant has all testing
equipment to perform mandatory tests related fresh and hardened concrete tests.
8. Contractor should continuously examine the ingredients (sand, coarse aggregate, cement, water) as per
the respective tests referenced by the Engineer, ensure the conformance to the approved mix designs.
If any deviation encountered, contractor should modify the design of mix.
4.3 Formwork
9. Formworks are made with the basic materials such as plywood and timbers. Ties and anchorage are
maintained by tie rods and studs. This is a time consuming situation and the concrete finishing quality
is affected adversely. The workmanship at formworks is poor and not comply with the specification and
code requirements.
4.4 Casting Concrete

10. Contractor should ensure that only the qualified and trained workers are allowed to work in the project
to achieve the required quality standard.
11. Periodic control and performance monitoring should be closely made on these workers at the job site.
Page 13 of 15

12. All workers, supervisors and engineers should be imparted for the requirements of works along with
the method statements, specifications, producer recommendation and international codes and
specifications.
13. Toolbox meetings and training sessions should be implemented for different activities and those
trainings shall be kept continuously executed.
14. All training records should be archived.
4.5 Concrete Repair Works

15. Contractor shall use only the approved suitable concrete repairing materials.
16. It is requested from contractor to sort out the defect types, frequency of appearance and analysing the
repair methods.
17. Concrete repair team should be trained and periodically monitored to prevent any non-compliant
material or methods applied.
4.6 Architectural Works

- Contractor shall use only the approved materials, accessories for architectural works.
- Contractor shall use same manufacturer and supplier for increase the quality of architectural works.
18. Construction teams should be trained and periodically monitored to prevent any non-compliant
to achieve the required quality standard.
21. 3rd Party Lab. Staff should verify the quality of mortal, grout, concrete masonry units, etc. with periodic
tests
22. Contractor’s survey team should be sure the alignments of CMU and RCU items.
4.7 MEP Works

23. Contractor shall use only the approved piping’s, fittings and accessories for Sewerage & Vent system,
Storm drainage system, Water Supply System, Irrigation system and firefighting system.
24. Contractor shall install all piping's and fitting materials for a particular installation from a single source
manufacturer in order to avoid compatibility due to intermixing of products in order to avoid leaks
during testing.
25. Construction teams should be trained and periodically monitored to prevent any non-compliance
to achieve the required quality standard
28. Contractor to speed up and shall resubmit all NKY commented MEP shop drawings for review and
approval in order to accelerate the work activities in sites.
Page 14 of 15


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CUSTODIAN OF TWO HOLY MOSQUES KAP 2

SITE QUALITY OBSERVATION REPORT

NKY Architects & Engineers

Reinforced Concrete Structural Elements General Recommations

-1- 1. Deformed RCU during 1. Training during tool box talks to

NKY Architects & Engineers

NKY Architects & Engineers

NKY Architects & Engineers

Uncalibrated Oven and air meter

Calibrated crushing machine

NKY Architects & Engineers

Bathing Plate Aggregate Weight Scale

J&P SITE LAB.

NKY Architects & Engineers

See Page 7 See Page 7

Calibrated Electronic Scales

Calibrated Sieve Set and Sand Cone Set

Lab. General View

NKY Architects & Engineers

Items has been investigated for the Quality planning and

- Is there Any training programs available in the contractor’s YES OBSERVATION

NKY Architects & Engineers

Items has been observed during the investigation of the OBSERVATION

NKY Architects & Engineers

-Supporting / temporary equipment such as vibrators, N/A OBSERVATION

NKY Architects & Engineers

-Check if the approval is available for the special purpose N/A

-Check if the Quality Control team is adequate to cope with NO OBSERVATION

-Any Corrective Action or Preventive action records available YES (Partially)

NKY Architects & Engineers

4.1 Concrete Production (Batching, Mixing, Transporting and Handling)

4.2 Laboratory Testing

4.4 Casting Concrete

NKY Architects & Engineers

4.5 Concrete Repair Works

4.6 Architectural Works

4.7 MEP Works

NKY Architects & Engineers

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