Project : Lift Upgrading Programme G16B

Quality Assurance
&
Quality Control Plan

LBE CONSTRUCTION PTE LTD

The contents of this document provide the minimum level of quality from the fabricator contractor.
The contractor manual shall update and modify this manual for each project. The contractor shall
update any standards, procedures, and processes within this template to reflect the most recent
standards and provisions outline.
QP 1: Quality Plan Overview
Rev 1 , Date 20 Feb 2014

PURPOSE
To provide a plan that outlines the structural steel quality checks to be performed during
the Project. This plan defines the roles and responsibilities of QAQC and the Engineer
with respect to structural steel quality.

All fabrication activities associated with this Project will be completed under this quality
program. Only controlled products will be delivered. Elements will be fabricate / weld
with qualified welders following approved drawings using proper consumables and
equipment. Inspections and tests will be performed as outlined in this Plan to document
the construction is proper and meets Project requirements. Periodically, the process
will be refined based on worker-identified quality problems, inspection results,
satisfaction with the Project.

PRODUCTS AND MATERIALS

Quality tests and inspections will be performed during the production of the materials,
as materials arrive on the workshop, and as they are incorporated into the construction.
Tests and inspections will be performed by a quality personnel.

Suppliers will perform tests on materials as they are produced. Prior to the material
arriving on the workshop, visual inspection will be thoroughly inspected if the material
meets requirements. The QC personnel will also identify and review the Project
requirements with the supplier/clients.

Products and materials are identified from the mill certificate and FPC. Where
appropriate, a unique number will be assigned and a tag attached. Where traceability is
required, the location of the product or material will be recorded.

Handling

Steel member are handled on workshop/site in accordance with client's

recommendations and good construction practice. When materials arrive at the Project
Site, any damage or deficiency will be noted during or after transportation of steel
member. The steel member will be used or stored as appropriate for the material.

The Work will be conducted following the proper test procedure and documented on the
proper form accordingly.

Packing slips, mill certificates, or other documents from the supplier showing
conformance to requirements will be reviewed by QC and QA personnel and retained
by QA.

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Storage

Products or materials not immediately used will be stored. Material for indoor storage is
placed in bins, shelving, racks, or pallets and positioned in neat and orderly condition
for ease of retrieval. Material stored outdoors is placed on adequate protected as
required.

Protection

Some products and materials will require special measures to protect them from
degradation. The requirements will be followed in providing the proper environment for
the products and materials. The Project Manager will be responsible for providing
proper conditions.

QUALITY TESTING AND INSPECTION

During fabrication, various elements will be checked and compared to the projects
requirements. These checks will be performed following the appropriate procedure and
documented on the proper form. Testing will be performed to the Project minimums.

All documentation shall be recorded on Data.

Any inspection performed by third party does not relieve the manufacturer of its quality
management responsibilities.

CONTROL OF MONITORING AND MEASURING DEVICES

Monitoring and measuring equipment used on the Project will be appropriate for the
work being performed, in working order, and calibrated periodically. When not in use,
the devices will be protected from damage and stored in accordance with
manufacturer’s as well as Owner’s requirements. Records of the calibration will be
maintained.

QUALITY RECORDS

Test forms, Non Destructive Report will be provided to the client / consultant through
document control. Data from these tests will be recorded accordingly in Manufacturer
Data Reports.

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NON-CONFORMING WORK / STOP WORK

Non-conforming work and stop work orders will be performed in accordance with the
Quality Management Plan.

QP 2: Inspection Stages
2.1 - Incoming Materials (Raw / Galvanized Members)

2.1.1
Check materials/member for straightness, or any damage on surface. Materials should
be grade A-D (rusty surface acceptable criteria). Any defects found should return back
to supplier or report to Engineer.

2.1.2
Heat No. and Type of Grade material should also be stated with relevants Mill
Certificates accordingly (2.1, 2.2, 3.1, 3.2) FPC (Factory Production Certificates) should
also be produced based on projects specifications requirements.

2.1.3
Released for next stage etc; sand blasting / galvanizing. (Optional)

2.2 - Material Delivery to Factory

2.2.1
Check materials/member for any damage or out quantity prior to delivery.

2.2.2
Gather all relevants documents such as Blasting Report or Galvanised Report or follow
by Painting DFT Report sign by Paint Inspector.

2.2.3
Released for next stage. (Cutting)

2.3 – Edge Preparation / Fit Up Inspection (Before Welding)

2.3.1
Dimension check for edge preparation before welding based on Approved Drawing. (Or
latest revision drawings)

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2.3.2
Joint should be free from contaminants, oil or grease. Paint should be remove by
grinding.

2.3.3
Welder should be fully qualified before proceeding any joint welds. To make sure joint
based on Welding Procedure Specification.

2.3.4
Consumables of welding should be in proper storage. If welder using SMAW (MMA)
process, should stored electrodes consumables in a small quiver. To ensure correct of
Active/Inert Gas and correct polarity used based on Welding Procedure Specifications.

2.3.5
Proper fairing or jigs to be fixed to avoid any large distortion during welding.

2.4 – Visual of Weldment Inspection (After Welding)

2.4.1
Surface preparation of weldments such as Grinding should be done prior to Visual
Inspection.

2.4.2
Weldment should be thoroughly clean such as remove of spatters etc; for the ease of
Visual weldments. Discontinuities should be check and marked. Rectification should be
follow up by grinding or touch up by welding.

2.4.3
Size or profile of weldments should be check by using Welding gauge. Dimensioanl
check should also be considered after welding. This is to ensure no distortion/restrain of
materials occurs.

2.4.4
Released for Non Destructive Testing

2.5 – NDE of Weldments

2.5.1
Engagement of Third party testing agency to conduct testing

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2.5.2
Review of Tester competency Qualification certificates and ensure that testing
equipment obtain valid calibration certificates.

2.5.3
Conduct testing (Magnetic Particles or Ultrasonic Testing)

2.5.4
Pass – Proceed to next stage
Fail – Rework and re-test

2.6 – Application of Painting System

2.6.1
Mixing ratio of paint based on product data sheet by the manufacturer recommendation.

2.6.2
Surface preparation of material to be apply. This may be done by grinding or
powerbrush.

2.6.3
Application of primer follow by Topcoat. This will also be guided through product data
sheet

2.6.4
DFT check for microns require by project specification after the elapsed time (fully
cured).

2.7 – Installation of chemical bolts

2.7.1
Drill of concrete wall to requirement depths. Throughly blow up dusted concrete inside
the holes. This is to prevent unbonding chemical and the concrete.

2.7.2
Application of chemical based on the manufacturer recommendation.

2.7.3
Insert bolts by twisting through the concrete walls. This is to ensure fully chemical
touches the bolts effectively.
2.8 – Adhesion / Pull Out Testing of bolts (on site)

2.8.1

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Engagement of supplier tester to conduct testing.

2.8.2
Selection for numbers of bolts should refer to client project specification contract.

2.8.3
Pass – Proceed to next stage of work
Fail – Refer to client

2.9 – Material deliver on site

2.9.1
Check materials/member for any damage or out of quantity during transportation. To
liase/report with production team if any defects occurs.

3.0 – Alignment / Verticality Check

3.0.1
To check verticality of member etc: within project specification tolerances deviation. By
using either Plumb bob / Theodeolite

3.0.2
To records any out deviation thoroughly

3.1 – Bolt Tighthening / Torque Test Inspection

3.1.1
Visuallly review bolts connection based on approved drawings. Grade and size
required.

3.1.2
To ensure Torque test Equipment obtain a valid Calibration certificate and to produce
torque values range from the manufacture based on project specifications.

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 Quality Assurance : Shariff Joey

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