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Process Control Plan

PROCESS: Magnetic Extensometer installation and Monitoring

PROCESS : MAGNETIC EXTENSONMETER INSTALLATION AND MONITORING

PCP No: N5012-CS-PCP-0013-03 Construction Lot No:

Date: 8/04/14

THIS PROCESS CONTROL PLAN COMPRISES THE FOLLOWING DOCUMENTS AND IS


APPROVED FOR USE:

PART 1 Inspection and Test Plan

PART 2 Lot Verification Checklist

PART 3 PCP Briefing Record

Scope:

This document encompasses the procedures and requirements around the installation and monitoring of
Magnetic Extensometers on site.

Reference Documentation:

Related Documents, Specifications and Code of Practice:

SH16-4-G-SP-2010-01 – Monitoring and Instrumentation Specification


The Constructor shall be aware of the following documents including requirements under any Resource
Consents, Building Consents and permits issued for works on site. In the event of any ambiguity or
conflict, the following order of precedence shall apply:
 Resource Consent.
 Building Consents.
 Owner’s Minimum Requirements.
 Designer’s Instructions - Site Instructions.
 Drawings.
 Causeway Alliance Instrumentation Specification SH16-4-G-SP-2010.
 Manufacturers Specifications.
Drawings presenting the location of instrumentation to be installed as part of this project are:
 SH16-4-G-DG-4701 to SH16-4-G-DG-4716, sheets 1 to 16.
 SH16-4-G-DG-4730 to SH16-4-G-DG-4735
 SH16-1-S-DG-3103 and SH16-3-S-DG-3605
Drawings detailing the instrumentation to be installed as part of this project are:
 SH16-4-G-DG-4736 to SH16-4-G-DG-4739.
The drawing presenting instrumentation tables and monitoring frequencies (including alert and alarm
levels) plus notes is:
 SH16-4-G-DG-4740
Standards:

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Process Control Plan
PROCESS: Magnetic Extensometer installation and Monitoring

Special Instructions:

Geokon Instruction Manual Model 1900 Magnetic Extensometer

HOLD POINTS
The Constructor shall not proceed beyond a Hold Point until the Designer has expressly released the
Geotechnical Hold Point in writing.
The Constructor shall provide 24 hours advance notice to the Geotechnical Designer prior to reaching a
Hold Point so that the Designer can review the submission or witness the work process or test being
undertaken, and to expedite the release of the Hold Point. Where detailed assessment of the submission
is required the Geotechnical Designer will require one week assessing the submission prior to releasing
the hold point. The Constructor shall make adequate allowance in the construction program for the
Geotechnical Designer’s review of Hold Points.
Hold Points may also arise from non-conformances, and the Geotechnical Designer may nominate
additional Hold Points to be observed during construction activities.
The review by the Designer of a Hold Point does not relieve the Constructor of responsibility for
satisfactory execution or performance of the work.

Prepared By: Reviewed By: Approved By: Reviewed By:

Project SE / PE Quality Manager Construction Manager or Other


Nominee

Name Name Name Name

Dave Blanch Patrick Woodbourne


Signed Signed Signed Signed

Date Date Date Date

ITP Approved By Designer


As per Specification SH16-4-G- Signed: Date:
SP-2055-01 Section 5.1

Revision History: Status Date

1.0 IFC This Document

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Process Control Plan
PROCESS: Magnetic Extensometer installation and Monitoring

Item Provided By
Magnetic Extensometer Model 1900 Geokon 04700-01 Alliance Construction Team
Magnetic Datums Geokon 04700-02 Alliance Construction Team
Magnetic Extensometer Readout Geokon 09200-03 Alliance Construction Team
Socketed Ø32 mm PVC Pipe
Collapsible Pipe
Denso Tape McMillan Drilling
Black Tape McMillan Drilling
Kwik-Plug Bentonite McMillan Drilling
GP Cement McMillan Drilling

Installer

McMillan Drilling

Process

Process

1. Alliance Construction Team to provide installation programme to Alliance Design and Survey Teams.
(24 hour notice required)
2. Alliance Survey Team to upload extensometer location to Total Station from latest IFC revision
drawings.
3. Alliance Survey Team to peg extensometer location (Ground Level to be written on peg)
4. McMillan Drilling to core and box unless otherwise instructed to “Stable Ground”
5. McMillan Drilling to contact Alliance Design Team when “Stable Ground” reached
6. Alliance Design Team to inspect and instruct McMillan Drilling depth of end of hole and depth of
magnetic spiders
7. McMillan Drilling to core and box to end of hole
8. McMillan Drilling to flush drill hole
9. McMillan Drilling to prefabricate on Alliance Design Team instruction magnetic extensometer (photo to
be taken of all prefabricated Magnetic Extensometers and Magnetic Datum)
10. McMillan Drilling to trial release all magnetic spiders prior to installation.
11. McMillan Drilling to lower prefabricated magnetic extensometer to end of hole
12. Alliance Geotechnical/ Design Team to read magnets and approve location or instruct that magnets
need to be relocate (prefabricated magnetic extensometer will need to be removed from well to
relocate Magnets)
13. McMillan Drilling on approval of location of magnets to gradually remove casing and tremmie line
backfill with Bentonite cement mix as per Instrumentation and Monitoring Typical Details
14. McMillan Drilling to release magnetic spiders
15. Alliance Geotechnical Team to complete baseline readings
16. Alliance Geotechnical Team to upload baseline to electronic register
17. Alliance Survey Team to as-built installed inclinometer
18. Alliance Construction Team to forwarded as-built and QA information to Alliance Design Team
19. Instrument monitoring to be schedule via electronic register

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Process Control Plan
PROCESS: Magnetic Extensometer installation and Monitoring

Example of prefabricated magnetic extensometer

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PCP Inspection and Test Plan
PROCESS: Magnetic Extensometer installation and Monitoring

PCP No: N5012-CS-PCP-0013 Construction Lot No:


PART 1 OF PROCESS CONTROL PLAN

Hold (H) / Witness (W) Requirements


Conformance Criteria
No. Inspection / Test Point Responsibility Method Including Clause Reference and Frequency Records
specific criteria Independent
Contractor Designer
Verifier

Ensure JSEA, TMP, and ESCP are in


Each
Approved JSEA, TMP, Document place, understood, and signed off by JSEA / TMP /
1 Engineer Construction
and ESCP Review all personnel involved in completing ESCP
Lot
the task.

Staff to be briefed in the content of the


PCP and are aware of the Quality
Brief / Prior start of Signed Briefing
2 Briefing Record Engineer Requirements for this process:
Communicate work Record
As per - “Our Way” Alliance
procedure

Check that all Plant is approved for


Prior start of
3 Plant Engineer Visual the area and that plant proposed will ITP Sign Off
work
not adversely affect the works

Ensure Design and Engineer Review Latest Design Drawings Prior start of
4 ITP Sign Off
Drawings are IFC Documents work

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PCP Inspection and Test Plan
PROCESS: Magnetic Extensometer installation and Monitoring

PCP No: N5012-CS-PCP-0013 Construction Lot No:


PART 1 OF PROCESS CONTROL PLAN

Hold (H) / Witness (W) Requirements


Conformance Criteria
No. Inspection / Test Point Responsibility Method Including Clause Reference and Frequency Records
specific criteria Independent
Contractor Designer
Verifier

Instrumentation is to be installed and


monitored by geotechnical
subcontractors/specialists
experienced in the installation and
monitoring of these types of
Engineer / Preconstruction geotechnical instrumentation. All Prior start of
5 Installation WP ITP Sign Off
Designer Approval installations shall be in accordance work
with the manufacturers’
recommendations and instructions
(where applicable) and in accordance
with Specification SH16-4-G-SP-
2010-01 Section 6.0.

The Constructor shall obtain the


Designer’s approval of proposed
instrumentation i.e. make and model,
installation subcontractors/ specialists
Engineer / Preconstruction Prior start of
6 Instrumentation and monitoring specialists prior to WP ITP Sign Off
Designer Approval work
installation of instrumentation – As per
Monitoring and Instrumentation
Specification SH16-4-G-SP-2010-01
Section 6.1

Title: Magnetic Extensometer installation and Monitoring Date Published: 8/04/2014 Page 6 of 16
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PCP Inspection and Test Plan
PROCESS: Magnetic Extensometer installation and Monitoring

PCP No: N5012-CS-PCP-0013 Construction Lot No:


PART 1 OF PROCESS CONTROL PLAN

Hold (H) / Witness (W) Requirements


Conformance Criteria
No. Inspection / Test Point Responsibility Method Including Clause Reference and Frequency Records
specific criteria Independent
Contractor Designer
Verifier

The Constructor shall ensure all


instrumentation, including all cable
lines, are located in plan and
Engineer / elevation by engineering survey
7 Survey Location As-built Each item WP ITP Sign Off
Surveyor immediately upon installation. As per
Monitoring and Instrumentation
Specification SH16-4-G-SP-2010-01
Section 6.2

Instrumentation shall be installed as


early as practical Consultation with
Engineer / Preconstruction the Designer shall be undertaken prior Prior start of
8 Installation Programme WP ITP Sign Off
Designer Approval to finalising the instrumentation work
installation program. SH16-4-G-SP-
2010-01 Section 6.3

Establish Baseline Engineer / Site Inspection / The Constructor shall take baseline Commencemen HP Approval by
Levels Survey Team / Visual readings of all monitoring equipment t of earthworks Geotechnical
Designer to demonstrate that the instruments within 20m of Designer
are working correctly, and to establish instrumentation confirmed by
baseline behaviour of the ground. or Hold Point
The number of base readings and Bridge Piling/ Release Form
9
duration between successive base Bridge
readings shall not be less than two Widening
separate readings 3 days apart. As Works
per Monitoring and Instrumentation
Specification SH16-4-G-SP-2010-01
Section 6.4

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PCP Inspection and Test Plan
PROCESS: Magnetic Extensometer installation and Monitoring

PCP No: N5012-CS-PCP-0013 Construction Lot No:


PART 1 OF PROCESS CONTROL PLAN

Hold (H) / Witness (W) Requirements


Conformance Criteria
No. Inspection / Test Point Responsibility Method Including Clause Reference and Frequency Records
specific criteria Independent
Contractor Designer
Verifier

Protection of Engineer / Site Inspection / Construction monitoring must be As per drawing WP ITP Sign Off
Instrumentation Designer Visual protected at all times against any SH16-4-G-DG-
potential damage. Fill placement 4740
10 around the instruments shall be
undertaken by manual methods within
a distance of 1m. Specification SH16-
4-G-SP-2010-01 Section 6.5

As-built QA/ QC Report Engineer / As-built As-built reports, including approved Each item WP ITP Sign Off
Survey Team / QA/QC documentation to be supplied
11 Designer to designer within 2 days of
installation Specification SH16-4-G-
SP-2010-01 Section 6.3

Monitoring Frequency Engineer / Site Inspection / Monitoring frequency will be as per As per drawing HP Approval by
Designer Visual drawing SH16-4-G-DG-4740 any SH16-4-G-DG- Geotechnical
reduction in monitoring frequency will 4740 Designer
12
require designer approval confirmed
Specification SH16-4-G-SP-2010-01 d by Hold Point
Section 6.6 & 18.0 Release Form

13 Commencement of Engineer / Site Inspection / Where Trigger and/or Design Levels As per drawing HP Approval by
Earthworks or Bridge Designer Visual are met or exceeded for Settlement SH16-4-G-DG- Geotechnical
widening after Trigger Pegs, Plates or Inclinometers i.e. Ma 4740 Designer
Event exceeds 0.4 a Hold Point may (at the confirmed by
discretion of the Designer) be Hold Point
instituted to halt works As per Release Form

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PCP Inspection and Test Plan
PROCESS: Magnetic Extensometer installation and Monitoring

PCP No: N5012-CS-PCP-0013 Construction Lot No:


PART 1 OF PROCESS CONTROL PLAN

Hold (H) / Witness (W) Requirements


Conformance Criteria
No. Inspection / Test Point Responsibility Method Including Clause Reference and Frequency Records
specific criteria Independent
Contractor Designer
Verifier

Specification SH16-4-G-SP-2010-01
Section 18.0

Monitoring Reports Engineer / Electronic Monitoring records shall be promptly As per drawing WP ITP Sign Off
Designer database input and maintained in an easily SH16-4-G-DG-
accessible electronic database, 4740
14
accessible to the Designer.
Specification SH16-4-G-SP-2010-01
Section 6.0

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PROCESS: Magnetic Extensometer installation and Monitoring

PCP No: N5012-CS-PCP-0013 Construction Lot No:


PART 1 OF PROCESS CONTROL PLAN

Hold (H) / Witness (W) Requirements


Records
Conformance Criteria
No. Inspection / Test Point Responsibility Method Including Clause Reference and specific Frequency
criteria Independent
Contractor Designer
Verifier

Settlement period has Engineer / Survey Analysis On the basis of continuous Each item HP Approval by
been completed and Designer observation of the preload/surcharge Geotechnical
monitoring completed monitoring results the Designer will Designer
15 notify the Constructor when the confirmed by
preload/surcharge can be removed. Hold Point
As per Monitoring and Instrumentation Release Form
Specification SH16-4-G-SP-2055

Ownership Engineer / Handover Instrumentation to remain in place Each item WP Operation and
Designer where practical and become the Maintenance
16
property of NZTA Specification SH16- Manual
4-G-SP-2010-01 Section 6.0

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Lot Verification Checklist
PROCESS: Magnetic Extensometer installation and Monitoring
PCP No: N5012-CS-PCP-0013 PART 2 OF PROCESS CONTROL PLAN

Lot No:

Magnetic Date Installed:


Extensometer (S) ID#:

Installed By:

Readout #: Calibration Due:

Surveyed Ground Up Stand Height of


Level: Ø32 mm PVC Pipe:

Datum Depth to be Depth Installed:


Installed:

Depth Magnet 1 to be Depth Installed:


Installed:

Depth Magnet 2 to be Depth Installed:


Installed:

Depth Magnet 3 to be Depth Installed:


Installed:

Depth Magnet 4 to be Depth Installed:


Installed:

Depth Magnet 5 to be Depth Installed:


Installed:

Depth Magnet 6 to be Depth Installed:


Installed:

No Item Resp Satisfactory Remarks Initial

1.0 Preliminary

1.1 All Drawings are IFC and Latest Revision SE Yes No

Equipment Approved For Use By Design


1.2 SE Yes No
Team

Installation Programme Approved by SE/


1.3 Yes No
Design Team DT

2.0 Installation

Set Out by Construction Alliance Survey


2.1 ST Yes No
Team

Embedded Depth and Spider locations


2.2 SE Yes No
Provided by Design Team

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Lot Verification Checklist
PROCESS: Magnetic Extensometer installation and Monitoring
PCP No: N5012-CS-PCP-0013 PART 2 OF PROCESS CONTROL PLAN

No Item Resp Satisfactory Remarks Initial

Photos attached of each spider & datum


showing
 chains to prevent spiders releasing
2.3  attachment of Collapsible Pipe to top SE Yes No
and bottom of spider
 attachment of release cords to exto tube
 attachment of top stop (Hose Clamp)

Trial release all magnetic spiders prior


2.4 SE Yes No
to installation
Design Team Approval to release
2.5 DT Yes No
magnetic spiders
2.6 Grout Sample Taken SE Yes No

2.7 Core boxed and Stored SE Yes No

2.8 Instrumentation Protection Installed SE Yes No

Area tidy Installation Complete Final


2.9 SE Yes No
Inspection Done.

As-built, including QA/QC documentation


2.10 supplied to designer within 2 days of SE Yes No
installation

3.0 Baseline Establishment

3 Readings Taken Prior to Commencement


of Construction. Sign off of Monitoring
and Instrumentation Specification Hold SE/ HP
3.1 Yes No
Point #1 – Commencement of DT No_____________
Earthworks Within 20m of
Instrumentation

No Item Resp Satisfactory Remarks Initial

4.0 Monitoring

Instrument added to Electronic Monitoring


4.1 SE Yes No
Register

Conformance / Verification Statement:


I hereby certify that this closed lot conforms in all respects with the standards and requirements specified in the Contract
Documents. The lot verification records are complete and any non-conformances have been dispositioned in
accordance with the contract requirements.
Prepared by: Reviewed by: Approved by: Project Doc. No. Rev. Date

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PROCESS: Magnetic Extensometer installation and Monitoring
PCP No: N5012-CS-PCP-0013 PART 2 OF PROCESS CONTROL PLAN
Readings

Lot No:

Magnetic
Extensometer (S) ID#:

Read By: Date Read:

Readout #: Calibration Due:

Readings

Item Depth* (m)

Datum Magnet

Magnet 1

Magnet 2

Magnet 3

Magnet 4

Magnet 5

Magnet 6
* Measurement are to be taken from the bottom up from the point at which the second “beep”
sounds
(there are 2 “beeps” approx 10mm apart).

No Item Resp Satisfactory Remarks Initial

Monitoring

Instrumentation Protection Checked


1 GEO Yes No
Before Leaving

Readings Uploaded to Electronic


2 GEO Yes No
Register

Action Complete: Date

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PROCESS: Magnetic Extensometer installation and Monitoring
PCP No: N5012-CS-PCP-0013 PART 2 OF PROCESS CONTROL PLAN

Read By: Date Read:

Probe #: Calibration Due:

Readings Measurement are to be taken from the bottom up from the point at which the second “beep” sounds (there are 2 “beeps” approx 10mm
apart).

ID # Datum Magnet Magnet 1 Magnet 2 Magnet 3 Magnet 4 Magnet 5 Magnet 6

1170-N-E09

1320-N-E08

1400-N-E07

1600-N-E06

1700-N-E05

1890-N-E04

2000-N-E03

2200-N-E02

2400-S-E01

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PROCESS: Magnetic Extensometer installation and Monitoring
PCP No: N5012-CS-PCP-0013 PART 2 OF PROCESS CONTROL PLAN

Calibration to be completed annually

By: Date:

Probe #: Next Calibration Due:

Serial #

No Item Resp Satisfactory Remarks

5.0 Calibration

1 Visual inspection completed GEO Yes No

Probe activation checked with


2 GEO Yes No
magnet

Random side by side measurements


3 GEO Yes No
taken to check graduations

Action Complete: Date

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PCP Briefing Record
PROCESS: Magnetic Extensometer installation and Monitoring

PCP No: N5012-CS-PCP-0013


PART 3 OF PROCESS CONTROL PLAN

We the undersigned have been briefed in the content of this PCP and are aware of the Quality requirements
for this process:

Name Company / Title Signature Date

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