KAMOA KAKULA COPPER

A World Class Copper Mine

 AGENDA

01 02 03 04 05 06

INTRODUCTION ISO 9001 QUALITY QUALITY LESSONS MOTIVATION

TO QUALITY OVERVIEW ASSURANCE CONTROL LEARNED

DURATION +- 2 HOURS
CELLPHONES
SWITCHED OFF PLEASE
Your attitude and your decisions
determines the QUALITY outcome!

A negative mind will never give you a positive life!

PRESENTER

GERHARD EASTES – KCSA QMS MANAGER

• 37 yrs. Construction experience
• Total Quality Management – UNISA
• Currently studying NEBOSH International SHE Practitioner Prof.
• Welding & Fabrication Inspector Level. 2 Diploma – SAIW (Int)
• Welding Processes Expert. SMAW, TIG, GTAW, MIG, SAW, UWW.
• NDT (RT, UT, MT, PT)
• Mechanical Tech. Power Generation.
• Boilermaker.
• Electrical Tech.
• Corrosion Protection – (5 years. Group Five)
 Current & upcoming Projects

• Kakula Phase 1 & 2 De-bottlenecking project

• Kakula Village expansion project

• Kakula Smelter Project

• Kakula Smelter village project

• Kamoa 1 village project

• Kamoa centre of excellence

• and more…
 KAMOA 1 Copper Mine

..\..\2. KANSOKO\BLOCK PLAN\KAM-IH-2100-

00314-01 Rev B Kansoko Block Plan Layout_RV.pdf
KAMOA KAKULA COPPER SMELTER
KAMOA KAKULA COPPER SMELTER
QUALITY = ?
11
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03/09/2022

• Can I give you QUALITY?

• Can you give me QUALITY?
• Can you buy QUALITY?

• Quality is not tangible, you can not add it or build it into a

product afterwards.
• However, you can design and construct in accordance with
the required specifications and standards and if all the
requirements are met or exceeded will you have a high
quality product.

Managing quality means constantly pursuing excellence:

making sure that what your organisation does is fit for
purpose, and not only stays that way, but keeps improving.
12
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03/09/2022
 What is Quality?
What does it means to you?
It is “ the standard of something as measured against other things of a similar
kind, the degree of excellence of something ”

• Best quality materials used.

• Excellent corrosion protection.
• Expensive but affordable price.

ROLLS ROYCE GHOST

THE HISTORY & EVOLUTION OF QUALITY
 How where and when did it begin?

➢ Stone Age - Humans created tools from stone, wood, bones and other materials would
also could be used, but stone (in particular flint) was shaped for use as cutting tools and
weapons.
➢ Neolithic and the Bronze Age - Wheels were invented +- 5500 years ago Wheels from
stone and later wood.

Map +-14000
years old
 Quality evolved and improved during:

1st Industrial Revolution (Steam engines, trains, electricity) 1679 – late 18th century

Faraday’s Electric Generator 1831

 Quality evolved and improved during:

Second Industrial Revolution - Late 18th Century – Early 20th Century

(Advances in steel production, first production line for car manufacturing, airplanes,
electrification, telecoms etc.)
Pearl Street Station was the first
commercial central power plant 1882
 Quality evolved and improved during:

World War 1 primarily in Europe from the year 1914 to 1918

Quality evolved and improved during:

World War 2 - Sep 1, 1939 – Sep 2, 1945

 Quality evolved and improved during:

• World War 1 & 2 age of science – Atomic bombs where produced.

• Hiroshima & Nagasaki - Japan destroyed
1944
 Quality improved during
• 3rd Industrial Revolution 60’s – late 90’s (Space exploration –Apollo moon landing
Jul 16, 1969 – Jul 24, 1969

• 4th Industrial Revolution (Technical / Information) late 90’s current

(electronics and information technology to automate production)
Internet of things (IoT) and artificial intelligence (AI)
• Currently – race for deep space exploration – NASA, Elon Musk ; Richard Branson; China;
Russia etc. imagine the technology and QA/QC involved in this.
 What is a Quality Management System

KCSA QMS

QC QA
 The Father of Quality Management

William Edwards Deming Industrialist(1900-1993)

He is widely acknowledged as the leading management thinker in the field of quality. He

developed QMS principles.

American manufacturers rejected his Quality Management Principles which he profoundly

believed will improve the US economy.

In 1950, Japanese businessmen turned to Deming to help them rebuild an economy

shattered in World War II. W. Edwards Deming, who was an industrial expert, taught Japan’s
manufacturers how to produce top quality products economically. The Japanese used that
knowledge to turn the global economy on its head and beat U.S. industry at its own game by
exporting local produced goods with imported materials to the USA and various other
countries.

Deming's message to Japan's chief executives was that improving quality would reduce
expenses, while increasing productivity and market share.

He was involved with SONY, TOYOTA, NISSAN and many more Japanese companies.

A phrase he loved to used:

“If you can't describe what you are doing as a process, you don't know what you're doing.”
 Quality Management System (QMS)

A QMS is a set of policies, processes and procedures required for planning and execution
(production/development/service) in the core business area of an organization (i.e., areas
that can impact the organization’s ability to meet customer requirements). ISO 9001 is an
example of a Quality Management System.
The KCSA Quality Management System (QMS) is in accordance with ISO 9001-2015.

Applicable but not limited to the following:

• KCSA Document Management Process Procedure - ..\..\..\1. QMS DOCUMENTATION\13. DOCUMENT
CONTROL\1013-KMC-0000-DM-PRO-0002_Rev 00 - Document Management Process Procedure.pdf

• All Quality related documentation (Project Quality Plan, Correspondence, Data Books)
• Material Control (Material Receiving Inspection Reports, OSD Reports etc.)
• Construction Management.
• Project Management.
• Quality Audits – Internal, External.
• Non-Conformance Reports – Quality, SHE & Environmental.
 Quality Management System (QMS)

What is ISO 9001:2015

International Organization for Standardization – (abbreviated ISO)

ISO is an international standard-setting body composed of representatives from various national
standards organizations. Founded on 23 February 1947, the organization promotes worldwide
proprietary, industrial, and commercial standards.

ISO 9001:2015 specifies requirements for a quality management system when an organization:
a) needs to demonstrate its ability to consistently provide products and services that meet customer and
applicable statutory and regulatory requirements, and
b) aims to enhance customer satisfaction through the effective application of the system, including
processes for improvement of the system and the assurance of conformity to customer and applicable
statutory and regulatory requirements.
All the requirements of ISO 9001:2015 are generic and are intended to be applicable to any
organization, regardless of its type or size, or the products and services it provides.
 Quality Management System (QMS)

• ISO STANDARDS ARE INTERNATIONALLY AGREED BY EXPERTS

• Think of them as a formula that describes the best way of doing something.
• It could be about making a product, managing a process, delivering a service or
supplying materials – standards cover a huge range of activities.
• Standards are the distilled wisdom of people with expertise in their subject matter
and who know the needs of the organizations they represent – people such as
manufacturers, sellers, buyers, customers, trade associations, users or
regulators.
• Examples:
• ISO 9001 - Quality management standards to help work more efficiently and reduce
product failures.
• ISO 14000 - Environmental management standardsto help reduce environmental
impacts, reduce waste and be more sustainable.
• ISO 45001 - Health and safety standards to help reduce accidents in the workplace.

https://www.iso.org/home.html
 What are your responsibilities w.r.t. Quality Management?
KPA responsibilities in terms of the KCSA Quality Management System
• Understand and be knowledgeable about the KCSA Construction QMS (attend QMS inductions as required)
• Understand the importance of ISO 9001:2015 and ensure conformance.
• Ensure your company / department conform to KCSA Construction Procedures and Project specifications.
• Be knowledgeable of the applicable International Construction standards.
• Ensure legal liability compliance as per project design specifications (LMI load tests, pressure vessel tests,
concrete cube tests, soil compaction tests, NDT etc.) Mines Health and Safety Act 1996 (Act No. 29 of 1996) of the
Republic of South Africa; Occupational Health and Safety Act 85 of 1993 of the Republic of South Africa etc.
• Ensure you are knowledgeable of the KCSA Site Construction Procedure.
• Responsible for material receiving inspections and reports.
• Responsible for your installation inspections and capturing of inspection information. (P1, P2, P3)
• Ensure all SHEQ Packs and Data Books for your SOW are continually updated, signed off and handed over.
• Ensure effective handover of the installation / structure (Beneficial Occupation) to end user.
• Ensure the NCR process are strictly applied.
• Ensure the KCSA Technical Query procedure are followed when required.
• Attend required Construction, SHE and QMS meetings.
• Contribute and give input for the QMS Worker of the month motivation programme.
 What is Quality Assurance?

KCSA QMS

QA
 What is Quality Assurance (QA)?
• All the documentation required to prove the product or service delivered conforms to the
required standards and specifications: (Data Books, OEM Manuals, Test Records etc.)
• Quality Assurance (QA) is "part of quality management focused on providing confidence
that quality requirements will be fulfilled.

• The confidence provided by quality assurance is twofold - internally to management and

externally to customers, government agencies, regulators, certifiers, and third parties.

• Quality assurance relates to how a process is performed (Method Statement, QCP’s,

Inspection Checklists etc. or how a product is made,
 Why do we need Quality Assurance (QA)?
• To conform to applicable International Standards and Project design specifications. (ISO
9001:2015 - AWS, ASME, SANS)

• Comply with statutory and regulatory laws and by-laws of the relevant country.
(DRC Mining Code, Law No. 007/2002 of July 11, 2002.)

• It is a pre-requisite for submitting tenders. (Project Quality Plan)

• QA gives confidence and attract investors which will lead to new projects, more jobs and
profits. (Project reports)

• Your company can be considered as a preferred contractor or vendor.

DATA BOOK / SHEQ PACK
 SHEQ PACK
A SHEQ Pack is an individual set of documents required to ensure construction
compliance and conformance to the KCSA - SHE & QM Systems, project specifications
and the specified international construction standards.

Requirements:

• The SHEQ Pack shall follow an approved index. Civils SHEQ Pack Index.xlsx
• Each earthworks terrace shall have a SHEQ Pack.
• Each civils structure shall have a SHEQ Pack.
• Each equipment TAG number shall have a SHEQ Pack.
• Each piping line number shall have a SHEQ Pack.
• It must be kept at the point of work.
• The SHEQ Pack will be under the control of the contractor foreman / supervisor.
• The EPCM Supervisor is responsible to manage the SHEQ Pack.
• It shall be continually updated until completed and signed off.
• Will be integrated into the specific Data Book.
 DATA BOOKS

ISO 9001:2015 – CLAUSE 7.5 - DOCUMENTED INFORMATION – can be in any format as

contractually agreed - This is a requirement

• A Data Book is a set of documents serving as proof that all the required data
to construct the project is captured as per contractual agreement and
handed over to the client during close out of a project for future reference by
the client.
• It is a live document – continually updated until closed, accepted and
handed over.
• It follows an approved Index.

Responsibilities:
Extract from the Site Construction Procedure (DRA-0571-SITE-PR-1000-Rev0) states:
Construction quality documentation shall be continually maintained, and a site quality control
coordinator be appointed to assist the discipline site supervisors with this function, although the
ownership still remains with the appointed discipline site supervisor. This includes ensuring that
data books are generated and compiled progressively throughout the construction phase.
This is known as a technical Data file (Data Book). It should be kept available for at least the
time specified in the relevant Directive (e.g. for machinery this means for at least 10 years).

The file is required so that as the manufacturer you can demonstrate with appropriately
detailed documentation, calculations, and drawings, how your product complies with all
relevant Directives, and so is safe during all phases of its life.

•Information concerning the products design assessment and construction, including

information showing how relevant essential requirements have been met (which may include
references to technical standards applied).
•The conformity assessment procedure applied to the product.
•A copy of the Declaration of Conformity (and any other Declarations of conformity or
Incorporation relevant to the product or its subassemblies).
•A copy of the User Instructions
•Details of relevant research and test reports
•And where a series of products are made, details of the quality systems to assure the safety
of those products.
Normally the technical file does not have to be permanently available in material form, nor
located within the territory of the Community, provided it is capable of being assembled and
made available in a reasonable period.
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DRAWINGS
ISSUED FOR CONSTRUCTION (IFC) DRAWING
This is a Revision 0 drawing issued by the design office to site.

AS-BUILT DRAWING
Drawing with no changes, must be stamped and signed as “As-built”.
This shows the Contractor have reviewed the drawing and scope
associated and there are no relevant TQ’s and the work is as per
design.
RED LINE DRAWING
• Changes to the drawing shall be made in red pen with each
drawing to be stamped and signed as “Red Line” and confirmed
and signed of by the site Quantity Surveyor responsible.
• Each change must reference the approved Technical Query(TQ)
that was utilized to gain approval of the change.
• ISOMETRIC hand drawn drawings shall reference the IFC drawing
number and revision number.
• Red line drawings shall be returned to the design office to capture
all the changes and a new revision “As Build” drawing will replace
the superseded revision.
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DRAWINGS
BURIED SERVICES DRAWING
• All “Buried Services” shall be captured on As-Built drawings together with
the survey data.
• All drawings where the excavation sizes differ must be marked up with red
pen, accompanied by relevant survey data, and confirmed and signed of by the
site Quantity Surveyor and responsible Engineer.

CONTROL OF SUPERSEDED DRAWINGS

• Ensure your organisation has a Procedure to control superseded IFC
drawings.
• Remove old rev. drawings from site and replace with the latest rev.
drawings.
• This is your responsibility to ensure it happens.
• This is also a Document Controller function.
 METHOD STATEMENT

• Method Statements can go by different names, such as Safety or Work Method

Statements or a Plan of work. Whatever the name the aim remains the same.
• A method statement describes how (the method), the job will be carried out safely.
• It should be written in a simple, easy to understand format.
• Long detailed documents are discouraged as people are more likely to read, understand
and follow simple instructions rather than a long set of complicated instructions.
• Method Statements are so important that in the construction sector, they are asked for
to form part of a construction tender to evaluate the company’s dedication to work
safely with the intention to deliver a product or service of the highest quality standards.
• The document must also identify the potential hazards and outline the necessary
precautions put in place to ensure everybody's safety not just the workers carrying out
the task.
 Quality Control Plan (QCP)
• The QCP is an essential tool required to plan and control construction &
inspection activities based on the approved Method Statement.

• Prior to construction, all QCP’s shall be reviewed and approved by the relevant
interested parties. (QA/QC Manager, Supervisor, QC Inspector, Engineer, Client)

• QCP’s clearly defines all installation activities, inspections and testing in order to
meet the Project Specific requirements.

• QCP’s details the following:

✓ Mandatory inspection and testing activities that need to be carried out
✓ Applicable procedures, reporting formats and acceptance criteria for each
activity.
✓ Intervention points for the relevant activities.
✓ Associated documents, forms and inspection
✓ Check lists to be completed.

NEW FORMAT - EARTHWORK & CIVIL QCP's.xls

 Quality Control Plan (QCP)
• Supervisors / Foreman shall ensure the intervention points are followed.

• The contractor Supervisor / Foreman shall be familiar with the applicable QCP’s.

• All the intervention points / activities SHALL be progressively signed off by all
parties on the QCP’s on a daily basis or as soon as practically possible.

• It shall not become a paper exercise to complete the Data Book!

• Any questions / concerns regarding the QCP’s can be directed to the Site Quality
Manager.
DEFINITION OF INTERVENTION POINTS:
A point of inspection in the QCP that requires the presence of the inspection team member/s:

H – Hold where the next stage of the construction process cannot proceed beyond this point
until an inspection has been performed and the required conditions indicated as met or
achieved.

W – Witness Construction cannot proceed beyond this point if the inspection team has not
attended, provided due notice of the activity has been given to the inspection attendees.

S - Surveillance may be performed by the inspection team – no given time required.

R - Review of the records are developed by the contractor to ensure that the relevant activity
has been performed satisfactory and that contractual requirements have been met.

V - Verification are required by the inspection team to ensure that the relevant activity has
been performed satisfactory and that contractual requirements have been met.

A - Action needs to be taken to execute an operation prior to intervention and inspection

Example: NDT.
Associated documents to the Quality Control Plan:
• CONSTRUCTION CERTIFICATE – Permission to contractor to start with construction.
• SAFE ACCESS HANDOVER CERTIFICATE – Give safe access to contractors and disciplines.
• C1 CERTIFICATE – Construction Completion Certificate.
• Drawings
• Checklists POST-CONCRETE CHECKLIST.xls
• Inspection Reports QC Inspector Inspection Report -1.xlsx
• Test Reports.
• Survey Records.
 Safe Access / Handover Certificate
Why?
• To ensure the work area is safe for the following trades to enter and share workspace.
• Follow Project Schedule
• Creates ownership and collaboration between teams.
• Eliminate standing time claims.
• 1. KC-CON-CERT-AHO Rev06.xlsx
 Request for Inspection (RFI)
• The RFI system ensures that all inspections are planned and documented.
• RFI`s shall be raised for hold (H) and witness (W) points as per the approved QCP.
• All RFI’s shall be complete and be descriptive in the nature of inspection required, date, time
and location of where the inspection must be carried out.
• Supporting documentation shall be attached to the RFI i.e. IFC Drawings, Isometric
Drawings, Red Line Drawings, Weld Maps, material certificates, etc.
• Work shall not proceed beyond (H) and witness (W) points and until RFI`s signed and the
punch inspection is accepted.
• If the inspection is rejected, the necessary rework has to be completed and another RFI
submitted.
• KCSA-RFI-001 - Request For Inspection Form - Rev01.docx
 PUNCH INSPECTION
Phase 1 Punch KCSA-PL-01 - Phase 1 Punch List - Rev0.xlsx
• The Phase 1 (P1) of inspection shall be between artisan and contractor Foreman /
Supervisor with reference to all applicable IFC drawings and construction
procedures.
• The Supervisor will make a list of punch items found during inspection stage and
note all actions to be taken, by who and the date to be completed.
• The Supervisor and artisan/s shall revisit the P1 punch list at the predetermined date
and time to ensure all punch items are worked off.

Phase 2 Punch KCSA-PL-02 - Phase 2 Punch List - Rev0.xlsx

• The Phase 2 (P2) Punch inspection will be between KCSA Supervisor, contractor
QC Inspector / Foreman / Supervisor with reference to applicable drawings.
• The completed P1 Punch List shall be available to confirm it was done.
• Record Punch items found during P2 Punch and note all actions to be taken, by Who
and date to be completed.
• Revisit the P2 Punch list at the predetermined date and time to ensure all punch
items are worked off.
• The KCSA Supervisor can report any deviations with a Non Conformance Report.
 P3 Punch KCSA-PL-03 - Phase 3 Punch List - Rev0.xlsx

• The Phase 3 (P3) Punch will be between KCSA Punch team, Contractor Supervisor,
QC Inspector, Engineer & KCSA SHE Officer.
• The Data Book for the completed SOW shall be presented to the KCSA Supervisor and
QMS Manager for review prior to the P3 Punch.
• The worked off P2 Punch List has to be presented for review.
• Make a list of Punch items found during this inspection stage.
• Record all “Wish List” CAT D items as per client comments.
• Note all Punch items and actions to be taken, by who and the target date to be completed.
• Revisit the P3 Punch list at a predetermined date and time to ensure all punch items
are worked off. (P3 Back Punch)
• List all exception items that can’t be worked off immediately with the consent from the client
representative / Commissioning manager and end user.
• Keep track of the exception items and close it out on the P3 Punch list as soon as it
resolved, inspected and accepted.
 Punch List Categories
CAT A - Any item / defect that could affect the Safety, Health and/or environmental
condition(s) of project personnel / any defect that may cause structural and or
equipment damage.
All CAT A items must therefore be rectified immediately before proceeding to the next
phase of Punch inspection or commissioning.

CAT B - Any item / defect that deviates from the IFC drawings, specifications and quality
requirements.
CAT B items has to be rectified by the agreed date on the punch list.
However, authorization must be given by the Client and or Commissioning manager to
allow commissioning to proceed.

CAT C - Any item / defect that deviates from the IFC drawings, specifications and quality
requirements.
It’s usually minor items, usually cosmetic, which can be rectified while commissioning
is progress.

Note that Type A, B and C defects must be rectified before the Contractor/Supplier is
released from the contractual obligations.

CAT D - Commonly referred to as the “wish list” items, which fall outside the relevant
contractor’s contractual scope of works and thus typically outside the project’s
original scope.
Definition of Category A Safety punch list Items:

• Floor grating missing, loose or not clipped down

• Hand railing inadequate, missing or loose
• Critical structural items loose or missing
• Guards missing, not fitting correctly or inadequate in guarding the moving machinery
• Safety covers missing on electrical equipment
• Emergency stops / trip wire systems not operable
• Safety warning signs missing
• Audible siren warning systems not operational
• Inadequate or no lighting
• Electrical equipment / cable / stop / start stations incomplete or outstanding
• Protection and interlocking systems not operational
• Missing / incomplete field instrumentation that supports protection and interlocking systems
• Design errors

• Un-grouted pumps, column bases, etc.

 Construction Completion Certificate – C1

This document serves as Confirmation that the Contractor has completed all construction
related works in accordance with relevant design drawings and project specifications.

The C1 Construction Completion Certificate can only be issued once all the following conditions
are met:

• All P3 Punch and exception items are closed out to the satisfaction of the client.
• Agreed exception items and CAT D items to be carried over to an Exception Items List as
agreed with Client / Commissioning manager and attached to the C1 Certificate.
• All Technical Queries are to be resolved and closed.
• All Concession Requests to be approved and closed.
• All NCR’s to be closed.
• To be a valid certificate it has to be signed off by all the appointed interested parties.
• KCSA-C1-CERT-001 - SMPP Sub-Area Construction Completion Acceptance
Certificate.docx
Sectional Beneficial Occupation Handover Certificate for Sub-Area

KCSA Sectional Beneficial Occupation for Sub-Area.docx

• Shall be done for all completed infrastructure projects from

EPCM or contractor to KCSA Construction.
• Shall be done for all Structural Steel Structures from
contractor to KCSA Construction.

C2-Sub-Area Pre-Commissioning Acceptance Certificate - PPT 3.docx

• Shall be done for handover from KCSA Construction to end

user (mining / operations etc.)
 KPA’s REMINDER

Your KPA responsibilities in terms of the KCSA Quality

Management System
• Ensure legal liability compliance as per project design specifications (LMI
load tests, pressure vessel tests, concrete cube tests, soil compaction tests,
NDT etc.) Mines Health and Safety Act 1996 (Act No. 29 of 1996) of the
Republic of South Africa; Occupational Health and Safety Act 85 of 1993 of
the Republic of South Africa etc.
• You are responsible for your installation inspections and capturing of
inspection information. (P1, P2, P3)
• Ensure all SHEQ Packs and Data Books for your SOW are continually
updated, signed off.
• Ensure Safe Access handover are done when required.
 KCSA Non-Conformance Report (NCR)
Why and when is an NCR required? KCSA-NCR-FOR-0001 Rev.02.xlsx

• To identify deviations from specification / process and or poor workmanship.

• Supporting documentation to be attached i.e. Photo’s, copies of drawings and
specifications, TQ, SI.
• Shall be registered with the Quality department and on a controlled register.
• Must be addressed to the relevant Discipline Manager, who will be ultimately
responsible for closing out the non conformance in a timeously manner.
• The Corrective and Preventative action shall be stipulated.
• The NCR must be actioned and closed within 3 weeks.

Cost of Non Conformance

The Quantity Surveyor / Engineer has to do the costing of all NCR’s and
agree to the final figure.
 PREVENTION OF NON-CONFORMANCES
You can prevent non-conforming equipment, work, services or products by:
• Read, understand and follow the Project Design Specifications, Project Quality Plan, Site Quality
Control Procedure, IFC drawings and applicable construction standards.
• Follow the Procedure to control superseded IFC drawings. Remove old rev. drawings and
replace it with the latest rev. drawings. (Document Controller function)
• The Foreman / Supervisor has to perform 1st line inspections.(Surveillance & Phase1 inspections)
• The QC Inspector shall do surveillance Inspections and reports. QC INSPECTOR INSPECTION REPORT.xlsx
• Report any deviations immediately to Engineer / management.
• Involve and play open cards with the client at all times. Do not hide mistakes!!
• Do Material receiving inspections and report damage. (OSD Reports) KC-OSD-RPT-01 -OSD Report.xlsx
• Do Self / Internal Audits.
• Have an Established and controlled Quarantine Store room / area. See next slide!
• Follow the Technical Query Note Procedure
• Use the Concession Request Procedure if necessary.
 OSD - Quarantine Store
• Material or equipment failing to satisfy the criteria for
acceptance after receiving inspection will be recorded and
reported as damaged, wrong type, undersupplied quantity or
over supplied quantity by the Material Controller in the Stores
Discrepancy Register and shall be stored in a secure,
controlled Quarantine Store area until it can be accepted for
service or replaced. The contractor QC Inspector shall
inspect the quarantined material and submit an OSD report to
the package Engineer for further action.

• Inspection, testing and measuring tools or equipment found

to be uncalibrated, calibration expired, damaged, defective,
unserviceable will be immediately returned back along with
an Unserviceable Tag duly signed by Certifying staff giving
details of the defect and shall be transferred to the quarantine
area. It is to recalibrated/rectified of its defect for taking back
in to the inventory again.

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KCSA Project Procedures & Specifications
Ignorance is no excuse. Familiarize yourself with the Project Specifications and ensure
conformance.
1. KCSA Construction Completion Procedure
2. KCSA Site Quality Control Procedure
3. Earthworks & Civils – SANS 1200 / 2001 Standards
4. Structural Steel, Platework Design Criteria
5. Piping Technical Specification
6. Bolting and Fixing Procedure
7. Fabrication Quality Control Procedure
8. Corrosion Protection Specification
9. Applicable Welding Procedure Specifications
10. NDT (Non Destructive Testing) Procedures
11. Pressure Testing Procedure – Piping, Vessels.
12. Control of Non-Conformance Procedure
13. Corrective and Preventative Action Procedure
14. Heat Fusion Joining Procedure (HDPE Welding)
15. Scaffolding Erection and Dismantling Procedure
16. Hot Dip Galvanizing Repair Procedure
17. Commissioning Procedure
 Specifications and Procedures

• ..\..\..\1. QMS DOCUMENTATION\1. KCSA PROJECT PROCEDURES\DRA-0571-HQC-PL-1119 Project

Quality Plan - Rev0 - 20180822.pdf

• ..\..\..\1. QMS DOCUMENTATION\1. KCSA PROJECT PROCEDURES\DRA-0571-SQC-PR-1100-Rev0

Site Quality Control Procedure.pdf

• ..\..\..\1. QMS DOCUMENTATION\1. KCSA PROJECT PROCEDURES\DRA-0571-SSP-DC-0403 Structural

Steel, Platework Design Criteria - Rev0 - 20180823.pdf

• ..\..\..\1. QMS DOCUMENTATION\1. KCSA PROJECT PROCEDURES\DRA-0571-SSP-SPC-0400-Rev0

Corrosion Protection Specification.pdf

• ..\..\..\1. QMS DOCUMENTATION\1. KCSA PROJECT PROCEDURES\DRA-MP-PROC-SPC-002 Piping

Technical Specification - Rev 9.pdf

• ..\..\..\1. QMS DOCUMENTATION\1. KCSA PROJECT PROCEDURES\KCSA-PROC-BF-001 - Bolting and

Fixing Procedure.pdf

• ..\..\..\1. QMS DOCUMENTATION\1. KCSA PROJECT PROCEDURES\EC&I Design Criteria - DRA-0571-

ECI-DC-0800 Rev 2.pdf
 Applicable Codes and Standards
What are the differences between Codes, Standards and Specifications.
All codes, standards, specifications, and guides are conceptually similar, but each has
a specific application and purpose.

A CODE is a body of laws arranged systematically for easy reference and use. Because
a code has a legal status, it is by definition mandatory, and uses words such as shall, will,
and must to express certain conditions and requirements, and to verify that those requirements are being
met.
Examples:
• AWS D1.1, Structural Steel Welding Code
• ASME B31.3 - Process Piping Code.

A STANDARD is established for use as a rule or basis of comparison in measuring quality, quantity, content,
relative value, etc.
Examples:
• SANS 1200 South African National Standard (SANS 2001-CM2 Earthworks, SANS 2001-CC2 t Concrete
works)
• ISO 9001: 2015 International Quality Management standard
• ISO 45001: 2018 International Health and Safety Management standard

A SPECIFICATION describes all pertinent technical information for a material,

product, system, or service, and indicates how to determine that the requirements have
been met.
 AWS D.1.1 STRUCTURAL WELDING - STEEL

03/09/2022 Footer 59
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 Applicable Regulations

• DRC Mining Code, Law No. 007/2002 of July 11, 2002.

• DRC Mining Regulations, Decree No. 038/2003 of 26 March 2003, as amended, and to
such amendments that may be promulgated during the period of the Works.

• Mines Health and Safety Act 1996 (Act No. 29 of 1996) of the Republic of South Africa.

• Occupational Health and Safety Act 85 of 1993 of the Republic of South Africa.
 9001:2015

What does ISO stand for?

A - International Standards Organisation
B - International Organisation for Standardization
C - International Seismographic Organisation
 9001:2015

What does ISO stand for?

B - International Organisation for Standardization
 9001:2015

What is the purpose of ISO 9001:2015?

A – To monitor seismographic statistics
B – To control Environmental Standards
C – To specify the requirements for a quality management system
D – Implementation of International Safety Standards
 9001:2015

What is the purpose of ISO 9001:2015?

C – To specify the requirements for a quality management system
 What is Quality Control?

KCSA QMS

QC
 What is Quality Control?

QC is the physical inspection aspect of the QMS by:

• Following the Intervention Points in a Quality Control Plan – H, W, V.

• Performing QC Surveillance Inspections.

• Attend planned Punch 1,2 & 3 Inspections.

• Filling out associated checklists

 Why do we need Quality Control ?
• To consistently produce, construct , manufacture or fabricate a product or deliver
a service within budget on time and in accordance with the relevant design
specifications and standards.
• To have control over the activities and processes involved in the above by
means of: (IFC Drawings, Construction Procedures, Method Statement, QCP – Hold, Witness points,
Installation checklists etc.)

• To identify deviations which can cause down time,

failure of equipment and prevent catastrophic events.
 WHAT WENT WRONG?
HOW WILL KCSA PREVENT THIS FROM HAPPENING AGAIN?

➢ Method Statements was approved, but not followed or not revised for new
conditions.
➢ Revise the MS to suit new conditions. Communicate the revised MS to the supervisors and

ensure adherence.
➢ Approved Quality Control Plans (QCP’s) was not followed.
➢ Contractor management shall ensure strict adherence to QCP’s especially the Hold and
Witness intervention points. A QCP will not be a paper exercise to complete and sign off a
Data Book. The Data Book will be rejected and the NCR process followed.

➢ Inspection Checklists was not done.

➢ Check lists are an associated document to a QCP at H, W, or Verification points and
therefore compulsory to prove that the intervention point was followed as per
specification.
➢ Very little Phase 1 Punch inspections not done.
➢ P1 Punch is compulsory for contractor site team. Will be seriously dealt with if not
done.
➢ Project Specifications ignored.
➢ Ignorance is no excuse! A deviation from specification is a Non-Conformance and
will be dealt with as such.
➢ The TQ system was used, but in some cases the opposite of what was
approved was done on site. Contractors did not wait for the TQN to be
addressed but, went ahead and do follow their own initiative.
➢ Every TQ SHALL follow the STQ Procedure from start to finish. Not adhering to the
procedure is a Non-Conformance and will be dealt with as such.
Water leaks due to loose
flanges or damaged gaskets
Poor workmanship
 WHAT WENT WRONG?

HOW WILL KCSA PREVENT THIS FROM HAPPENING AGAIN?

➢ Contractor supervisors and foremen had a bad attitude towards Quality Control.
➢ QA/QC Induction sessions with all supervisory staff to educate and make them aware
of the requirements and importance of QC.
➢ KCSA Construction team to be pro-actively involved to ensure the Quality
Standards are instilled.

➢ Contractor Supervisors ignore QC Inspectors when poor workmanship was pointed

out.
➢ Contractor management shall plan QC walkabouts with the respective QC Inspectors
and supervisors / foreman to address and eliminate poor workmanship and other QC
issues.
➢ NCR system shall be used to address poor workmanship. Cost to be determined by
the QS.
➢ A High number of Non-Conformance Reports was raised.
➢ A high number of NCR’s are an indication that specifications and procedures was not
followed! Every contractor receiving an NCR during Phase 2 shall do a presentation
the Construction Management team during the weekly QA/QC Management meeting.
It shall be stated what went wrong, what corrective action was taken and what
preventative action was initiated.
➢ Poor quality work done by artisans. Lazy artisans let unskilled labour do the
work.
➢ The above shall not be tolerated. When it is found the case, it will be dealt with at HR
level and consequences faced.
➢ Quantity (tonnage, meters, cube volumes) over Quality and Safety
➢ The Project schedule is the driver and will be respected, however taking shortcuts
compromising SHE and Quality due to time constraints will not be tolerated.
Equipment Damage
• Contractor had no approved MS for transporting or handling critical
equipment.
Data Books was neglected, not kept up to date.

➢ A Data Book is a contractual and legal binding document. It will be rejected if it’s found
not be in line with the approved index, not maintained and especially if required
documents are not completed and signed off.

➢ The above will be seen as breach of contract!

➢ Contractors will be held liable for all defects arising after installation.

➢ The Defect Liability Period clause in the contract will be applicable to all construction
activities.
BUILDING DEFECTS DUE TO POOR WORKMANSHIP
BUILDING DEFECTS DUE TO POOR WORKMANSHIP

DEFECTS DUE TO POOR WORKMANSHIP

USING DAMAGED and INFERIOR QUALITY TOOLS
DEFECTS DUE TO WRONG MORTAR / PLASTER MIX

INSTALLING WRONG SPEC CONDUITS

Using Oxy-Acetylene cutting and Electric arc welding close to
or on rubber lined equipment and HDPE Piping.
• No approved MS for this work
• No Hot Work Permit for this activity
Fire started whilst using Oxy-Acetylene cutting and Electric arc welding close to or on
rubber lined equipment.
• No approved MS for this work
• No Hot Work Permit for this activity

86
 A veld fire set HDPE Piping alight
Piping servitude was not cleared from
invading grass and bush.

87
 LEGAL LIABILITY

Ensure you have an

understanding of the MHSA
 LEGAL LIABILITY
Workers using uncertified Crawl beams and working at heights without safety harnesses. A stop
work notice was issued and NCR raised causing the contractor time delays.
Violation of:
• Mines Health and Safety Act 1996 (Act No. 29 of 1996) of the Republic of South Africa.
• Occupational Health and Safety Act 85 of 1993 of the Republic of South Africa.
Atrocious Welding
Wrong bolting practice
Poor Workmanship of Pipe support
Wrong bolting practice
Specifications
Non-Conformance to the Corrosion Protection Specification
• Get copies, read and understand the specifications. There are no excuses for ignorance.
Phase 1 - Corrosion Protection Specification was ignored in totality.
Poor Workmanship of Pipe support
Wrong bolting practice
SELF MADE TOOLS
NOT ALLOWED, NOT APPROVED, NOT SAFE!
CONTRACTOR QMS READINESS PROCEDURE
CONTRACTOR QMS READINESS PROCEDURE.docx
KCSA QMS requirements – Prior to mobilizing to site:
Upon award of the tender, the contractor shall submit to the KCSA Construction QMS Manager the following:
1. QMS Onboarding File with the following information:
• Project Quality Plan
• Site Quality Control Procedure
• Construction Completion Procedure.
• Document Control Procedure
• Material Control Procedure in place. (Material receiving inspection, OSD reports, Material Certificates)
• Control of Non-Conformance Procedure.
• Copy of contract describing the Scope of Work.
• Company Organizational Chart.
• Responsibility Matrix - RACI
• Name list of management, QC Inspector/s, supervision and artisans.
• CV’s of management, QC Inspectors, supervision and artisans with certified copies of qualifications.
2. Mock / Sample Data Book with the following information to be reviewed by KCSA Construction QMS Manager.
• Data Book Index per discipline
• Applicable Method Statements.
• Quality Control Plans per discipline.
• Applicable checklists as per QCP’s.

3. Legal Compliance Data File

This file shall be established to ensure all legal liability requirements in your scope are met and captured as per project requirements.
The following must be included:
• Electrical COC Certificates for compliant installations.
• Pressure Test Certificates for pressure vessels.(air receivers, boilers etc.)
• Pressure Test Certificates for high pressure piping.
• LMI load test certificates.
 Your KPA responsibilities in terms of the KCSA Quality Management System
• Ensure your company / department conform to KCSA Construction Procedures and Project specifications.
• Be knowledgeable of the applicable International Construction standards.
• Ensure legal liability compliance as per project design specifications (LMI load tests, pressure vessel tests,
concrete cube tests, soil compaction tests, NDT etc.) Mines Health and Safety Act 1996 (Act No. 29 of 1996) of the
Republic of South Africa; Occupational Health and Safety Act 85 of 1993 of the Republic of South Africa etc.
• Ensure you are knowledgeable of the KCSA Site Construction Procedure.
• Responsible for your installation inspections and capturing of inspection information. (P1, P2, P3)
• Ensure the KCSA Technical Query procedure are followed when required.
• Ensure Lessons Learned are captured for all completed installations.
 Why do we need Quality Control ?

Think of the strict QA/QC during the production of:

• Medicine (COVID-19 Vaccine)
• Spaceships
• Satellites
• Airplanes, cars etc.!
Richard Branson - Virgin Galactic Unity 2
Spaceship – the world's first private
spaceship
 WHY DO WE NEED QUALITY CONTROL ?

Think of the bolts holding the wings of an airplane together (type and torque requirements)
 BOLTING AND TORQUEING

WHY DO WE NEED TO TORQUE BOLTS?

• It is sound engineering practice!
• OEM requirements calls for it.
• Every bolt has a torque setting.
• Bolts are used to attach various members to form a safe structural unit.
 BOLTS, NUTS & WASHERS (Fasteners)
WHY DO WE NEED MATERIAL TEST REPORTS?
ISO 16228:2017 specifies the different types of fastener inspection documents issued by the
fastener manufacturer or distributor and/or by the external authorized representative on
specific request of the purchaser at the time of the order.
ISO 16228:2017 specifies requirements for the content of each fastener inspection
document, in conjunction with the order, the relevant standards and/or specified
requirements.
What types of “Certs” are typically available with fasteners?

1. CofC – Certificate of Conformance (or Compliance)

This is a statement that the product being supplied meets the customers (or industry)
specifications. No actual dimensions or physical properties need to be reported.

1. MTR –Material Test Report (also known as - Inspection Report, Test Report, Chem-Phys
Report)
Lists the results of the physical properties of the product. This type of test report typically
does not provide dimensional results. The Fastener Quality Acts requires that MTRs are
available for each Lot of grade marked and heat treated product and are to include the
chemical analysis of the material used to make the part and the results of any physical
testing (hardness, proof load, tensile).
 Why do bolts fail?
Main root causes that explain bolt failure:
▪ Design specifications was not followed.
▪ Bolts was of wrong grade / class was used.
▪ The Torque wrench calibration was out.
▪ The wrong torque value was applied to the bolt.
▪ The Approved Quality Control Plan (QCP) was not followed.
▪ Wrong tightening sequence.
▪ The tightening operation was forgotten.
▪ Time constraints.
▪ Human error / negligence lack of supervision witnessing the torque procedure.
▪ The torqueing procedure was allowed to be done by unqualified and inexperienced
personnel.
▪ The tightening tool was not accurate enough regarding tightening tolerances.
 Tools and equipment to be calibrated
and verified frequently
1. Multimeters, Meggers, Oscilloscope etc.
2. Torque wrenches & Torque multipliers.
3. Welding machines used for coded welding.
4. Welding Electrode baking, holding ovens and hot boxes.
5. Dumpy levels and Theodolites and Total Stations.
6. GPS Navigation devices – Airplanes, Boats & Ships.
7. High accuracy Digital measuring devices. (Laser range finder)
8. Vernier, Micrometer, Digital spirit level.
9. DFT gauge (Dry Film Thickness measuring Gauge for measuring paint film thickness)
10. Laboratory scales and test equipment.
International standards governing the calibration of torque wrenches are ISO 6789-
1:2017 and 6789-2:2017
INSPECTION & MEASURING TOOLS CALIBRATION CERTIFCATE REGISTER SHALL BE
KEPT AND MAINTAINED
BOLT TORQUE CHART
Bolt Torque Report Bolting & Fixing Procedure
..\KCSA-BTR-01 - Bolting ..\KCSA PROCEDURES & SPECS\KCSA-
Torque Inspection Report for PROC-BF-001 - Bolting and Fixing
Equipment.xlsx Procedure.pdf

Taper Lock Installation Checklist Pipe Flange Installation Checklist

..\KCSA-TLIC-01 - Taper Lock ..\PIPING & WELDING\KCSA-FICL-01 -
Installation Checklist.doc Flange Installation Check List.docx
 REAL DISASTER DUE TO HUMAN NEGLIGENCE
Continental Express Flight 2574 - September 11, 1991 Fatalities 14

The NTSB (National Transportation Safety Board) determined the probable causes of the
accident as follows:
"The failure of Continental Express maintenance and inspection personnel to adhere to proper
maintenance and quality assurance procedures for the airplane's horizontal stabilizer de-ice
boots that led to the sudden in-flight loss of the partially secured left horizontal stabilizer
leading edge and the immediate severe nose-down pitch over and breakup of the airplane.
Botched drainage construction undertaken by Carillion has been blamed for
the Stonehaven derailment which killed three people in August 2020.

However, the drainage system and associated earthworks had not been
constructed in accordance with the original design and so were not able to
safely accommodate the water flows on the morning of the derailment.
WHY DO WE NEED QUALITY CONTROL ?
TTRENCHING & BACKFILLING
WHY DO WE NEED QUALITY CONTROL during
TTRENCHING & BACKFILLING
 WHY DO WE NEED QUALITY CONTROL ?
TRENCH & BACKFILL SPECIFICATIONS KAM-IH-6320000-19186 Trenching & Backfilling.pdf
PEOPLE DIED IN REAL DISASTERS DUE TO POOR
WORKMANSHIP & NEGLIGENCE
 MOTIVATION
You can make a difference! How?
A Monthly award for the worker nominated by his peers who has produced outstanding
quality work will receive a certificate of excellence.
KCSA CONSTRUCTION MONTHLY QUALITY AWARD CERTIFICATE
QMS CERTIFICATE OF ATTENDANCE
 Other related QMS Induction sessions to follow

- In depth understanding of the KCSA QMS (QC Inspectors)

- Piping & Welding (understanding codes and standards requirements)

- QMS awareness for Artisans (per discipline)

- QMS awareness for semi-skilled workers

 TEST

What will you do to improve

and
ensure the quality of workmanship
is of world class standard
on any of the
KAMOA COPPER SA PROJECTS?
The end.