Quality - Assurance - Plan - QAP - For Concrete Works

Government of Nepal
Ministry of Local Development

Department of Local Infrastructure Development and Agricultural Roads
Rural Access Improvement & Decentralization Project
(IDA Grant H 525-NP)
Dhanusha
QUALITY ASSURANCE
PLAN FOR BRIDGE WORK
BAHHARAJA BRIDGE, RAIDP DHANUSHA
Contract Identification Number: RAIDP/W/NCB/DHA-7.4 /BRI/068-069: Bachharaja Bridg
Prepared by:
Arvind Kumar Jha
Planning, Supervision and Design Engineer, Dhanusha
MARCH, 2012
Quality Ass urance Plan for Bridge Construction
DDC/DTO, Dhanusha
Foreword to the Bridges Quality Assurance Plan
The Quality Assurance Plan maps out what, when and how things will be done. It is
a blueprint for a successful job.
The current Bachharaja river bridge construction programme, apart from donor supported one,
includes a large number of structures, among which a significant proportion are 25m span. These are
major structures by any standard, and involve a huge financial investment by GoN, RAIDP, Nepal.
The works are being constructed by national contractors, often with limited resources, and are
supervised by DDC/DTO/RAIDP staff working under difficult conditions in remote locations.
The Bridges QA Plan has been prepared in response to the declared needs of the field staff involved in
bridge construction. It covers the major issues raised by those staff, recognizing the l im i t ed
resourc es available. The docum ent is i nt ended to bri ng about increm ental changes in the
management of bridge construction by Contractors, with the longer term objective of improving
overall quality of construction. The scope of the QA Plan will be expanded in future revisions as
field divisions become familiar with the requirements and implementation of the QA processes.
The QA Plan is a tool to assist staff fulfills the technical and procedural requirements of the contract.
It must not be used as a substitute for the contract documents, which staff must be familiar with in
order to carry out their responsibilities effectively.
I am therefore very happy to formally sign off the Bridges QA Plan for issue to all working divisions
in Contractor. This is your document. It is your responsibility to make it work in the better interests of
the department and the people of Dhanusha, Nepal whom we serve.
…………………..
Chief Engineer
Ministry of Local Quality Ass urance Plan for Bridge Construction
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Contents
PART 1 DESCRIPTION
1. Introduction
1.1 Quality Control is not Quality Assurance
1.2 What will QA achieve?
1.3 The QA Plan is in 3 sections
1.4 Implementation of the QA Plan
1.5 Construction Monitoring
1.6 Additional Sections
2. Management and Organization

2.1 Parties to the contract
2.2 Employer
2.3 Engineer
2.4 Engineer’s Representative (ER)
2.5 Support staff
2.6 Staffing
2.7 Quality Accreditation
3. Quality Control in Construction

3.1 General
3.2 Materials storage and control on site
3.3 Temporary works
3.4 Preparatory works
3.5 Quality control tests of Materials
3.6 Quality Control of Workmanship
3.7 Quality Control Tests
3.8 Excavation
3.9 Mixing of Materials
3.10 Piling
3.11 False work
3.12 Concrete pour
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3.13 Approval of Preparatory Works

3.14 Non-compliance
4. Document Control
4.1 General
4.2 The Employer’s Representative
4.3 The Engineer
4.4 The Engineer’s Representative
4.5 Site Laboratory
4.6 As Built Drawings
4.7 Site Diaries and Record Photographs
5. Monitoring
5.1 Bridge Construction and Maintenance Circle
5.2 Contract Monitoring
5.3 Aspects of Monitoring
5.4 Outputs of Monitoring
5.5 What will monitoring achieve?
6. Payment
6.1 General
7. Settlement of Disputes
7.1 General
PART 2 CONTRACT QA PLAN
1. Introduction
1.1 General
1.2 Contract Details
1.3 Official Contract Staff
1.4 Contract Equipment and Facilities
1.5 Contract Filing System
1.6 Monitoring Procedures
1.7 Pre-Construction QA Workshop
Annex A Job Descriptions

Employer's Representative
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Engineer
Engineer's Representative
Materials Engineer
Structural Engineer
PART 3 QUALITY ASSURANCE FORMATS
1. Introduction
2. Testing
3. Inspection & Approval to Proceed
4. Records
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1. Introduction
Quality Assurance is about the control of systems, and specifically the establishment of a
clearly understood reproducible system that will ensure that projects are delivered
according to design, on time and within budget.
The purpose of the QA Plan is therefore to clearly set out exactly what is to be done, when it
will be done, by whom, and most importantly how it will be done. It is a User’s Manual that
Will help all of the staff involved in a project to deliver a successful job.
This QA Plan has been developed in response to requests by Contractors field staff for clearer
direction on roles and responsibilities in the management and supervision of bridge construction
projects being implemented by contractors employed by DDC, Dhanusha. The Plan has been
prepared primarily for larger structures, typically of 25m span and greater, nevertheless it is
also applicable to all structures other than simple pipe culverts.
Note
In the interests of simplicity and consistency the various contracting parties, officers and staff
mentioned in this document have been referred to in the male gender. It is nevertheless understood and
accepted that any of the positions referred to may be occupied by female staff in which case the
references in question are considered to imply to either gender.
1.1 Quality Control is not Quality Assurance
It is essential that everyone involved in a project clearly understand the difference between the terms
Control and Assurance. The following definitions should be of help.
Quality Control
The routine application, at prescribed
frequencies, of a system of procedures for the
sampling and testing of materials prior to
placing and following completion that ensures
that specified standards are achieved.
Quality Assurance
The identification of roles and responsibilities
of all parties, together with procedures and
systematic management to be followed that will
ensure that the Quality Control System is
implemented effectively.
In simple terms Quality Control is a system of established technical procedures that, if implemented
correctly, should ensure that individual elements of the overall construction
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works are completed to a prescribed standard. Each procedure relates to a specific aspect of the
works and usually involves a test or combination of tests to determine compliance or otherwise with a
Specification. QC does not specify “who, where and how” the procedures will be implemented.
Quality Assurance is a management system. It provides the essential guidance to the “who, when,
where and how.” It provides the operating procedures through which the QC system is implemented. If
implemented correctly it will ensure that the Quality Control system is effective and the overall works
are delivered to the agreed standards contained in the contract.
QC and QA cannot be separated. The two systems must be implemented together.
1.2 What will QA achieve?

The QA Plan has been introduced to help improve the management and supervision of construction
contracts. This will be achieved through the following steps
1. Standardization - of operating procedures
2. Consistency - in work practices
3. Familiarity - with responsibilities for each individual
4. Confidence - of all staff involved
5. Efficiency - in work output
6. Satisfaction - in a job done to the best of our ability
7. Pride - in a job well done and a project delivered to the best standards
8. All of which are vital to the effective QUALITY OF WORKS
It is important to understand that these steps describe a process that will lead to the end result. Each
step leads to the next and builds upon the predecessor.
1.3 The QA Plan is in 3 sections
This QA Plan has been kept simple. It is divided into three sections:
Part 1 provides a Description of the QA Plan, and highlights some of the major issues that must be
addressed. It should be used to familiarize staff with the overall requirements of the specific QA Plan
that will be developed for each contract.
Part 2 contains a blank QA Plan template that will be filled out and customized to suit each
particular contract. It is important that the DDC/Contractor supervision team prepare their own QA
Plan during the QA Workshop at the start of the contract1. This will promote ownership and ensure
clarity of purpose from the outset.
1
See 2.7 – Quality Accreditation

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Part 3 contains a series of simple templates to be used in the Site Record Books. These books
should be provided and maintained by the contractor. They will be filled in by his staff and approved
by the DDC/DTO/RAIDP supervisor as the works progress. The QA Plan is implemented through the
Site Record Books.
The QA Plan is a tool to assist staff fulfill the technical and procedural requirements of the
contract. It must not be used as a substitute for the contract documents, which staff must be
familiar with in order to carry out their responsibilities effectively.
1.4 Implementation of the QA Plan
The QA Plan must be understood by all staff directly involved with the management and supervision
of the c ontract. The Plan, staffing arrangem ents and procedures will be explained at a
QA Workshop to be convened by the DDC/DTO/RAIDP staff at the start of the contract.
1.5 Construction Monitoring
In addition to serving the prime function of assisting site staff in fulfilling technical and procedural
requirements of a contract, the QA Plan will also be used by the PCU/PSC/RAIDP Monitoring Team
as a basis for measuring contract performance against agreed standard procedures.
1.6 Additional Sections
The present version of the QA Plan deals only with construction supervision. Further sections will be
added in due course to cover other issues and further phases of the overall construction process. These
will include:
Design phase
Maintenance
Social and Gender Issues
Health, Safety and Welfare
Environment
2. Management and Organization
Senior management must define suitable staffing levels and assign responsibility and
authority for all project staff. These must be strictly adhered to for the duration of the
contract.

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2.1 Parties to the contract
There are three entities defined in the contract2 :

• Employer
• Contractor
• Engineer3
Other titles commonly used in contracts, such as Project Coordinator, Project Manager, Executive
Engineer, do not have a contractual basis and should therefore not are used in formal correspondence.
The names and designations of all staff involved in the management and supervision of the contract
will be included in Part 2.
2.2 Employer
The Employer is:

Government of Nepal
Department Of Local Infrastructure and Development Of Agricultural Road (DoLIDAR)
The Employer’s Representative is the officer who signs the contract on behalf of the Employer.
Depending on the size, nature and value of a contract this may be the Chief Engineer or at the Zone
level an Additional Chief Engineer, at Circle level a Superintending Engineer or at Division level a
Divisional Executive Engineer.
In most cases the Employer’s Representative will delegate some or most of his duties to subordinate
staff. It nevertheless remains his responsibility to ensure that those duties are discharged correctly.
The Employer’s Representative must be kept informed by the Engineer of contractual matters that
could give rise to claims or delay to the Works.
2.3 Engineer
The Engineer named in a contract may be an ACE, SE, PDE or EE depending on the size, nature and
value of the contract4. The Engineer is responsible for the administration and control of the contract,
and in particular the supervision of the Works to ensure that the Contractor fulfils the requirements of
the contract.
All powers under the contract remain with the Engineer, although he will usually delegate some or
most of his/her duties to the Engineer’s Representative, also named in the contract.
2.4 Engineer’s Representative (ER)
2
Standard Tender Documents issued by the Public Procurement Monitoring Office (PPMO), Nepal
3
This role can be performed either by the Employer or by a Consultant
4
The Engineer may or may not be the Employer’s Representative depending upon the size, nature and value of the contract.

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The Engineer will normally delegate in writing all or some of his powers under the contract to his
representative on site5, and will formally notify the Contractor of the powers in question prior t o
commencement of t h e W or k s . Notwithstanding an y d el eg at i on of p ow er s ,
responsibility for those powers remains with the Engineer.
On most projects the Engineer’s Representative is supported by field staff engaged on specific
activities (eg setting out, measurements, quality control tests, etc). Support staff are not authorized to
give instructions to the Contractor, nor either to accept or reject the works, responsibility for which
rests firmly with the DDC/DTO/RAIDP Engineer.
2.5 Support staff
The number of support staff required for a particular contract will depend upon the size and nature of
the works. A specific job description for each position will be issued in writing by the Engineer or
ER for the contract. For large bridge contracts each supervision team will include a Materials Engineer
responsible for overall quality control, and a qualified Structural Engineer. On smaller contracts the
responsibilities for materials and structures may be delegated to the Zone only if qualified staff is
available.
2.6 Staffing
It will be the ultimate responsibility of the Engineer to ensure that suitable staffs are
assigned to the contract supervision team.
The Engineer will decide the levels of supervision staff that are required for the contract. He should
only appoint suitably qualified and experienced staff to these positions, and may arrange additional
training for individuals should this be considered necessary. In the event that there are insufficient
qualified staff within a Sub-Division the Engineer must arrange for deputation of additional staff from
other locations where there are suitable staff available, or alternatively from Head Office. If staffs are
not available from these locations the Engineer may consider hiring from the private sector.
The Engineer will encourage a team approach to supervision by his supporting staff. Clear lines of
communication and reporting procedures will be established at the Pre-Construction Workshop.
5
It is accepted that in many cases the ER may be the Sub-Divisional Engineer and it is not feasible for him to be based at
site, as would be the case on larger and/or consultant supervised contracts

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The Engineer is responsible for ensuring that the contractor fulfills the requirements of the
Contract.
2.7 Quality Accreditation
The Engineer will conduct a Team-up QA Workshop with all staff assigned to the contract prior to the
commencement of the works. The purpose of the workshop is to ensure that everyone understands his
or her roles and responsibilities, and then to prepare the QA Plan for the contract. Staff will have the
opportunity during the workshop to clarify any issues regarding implementation of the contract.
At the end of the workshop all staff will be issued with a Certificate of Accreditation6, including
personal issue copies of the QA Plan, Job Description, Procedures and Contract Documents. Staff will
also be issued personally with all equipment (motor-cycle, mobile telephone, calculator, etc) deemed
necessary for them to fulfill their duties. A copy of the Certificate of Accreditation is contained in
Part 2.
The provision of a mobile telephone will allow field staff to notify the ER of problems on
site, eg failed quality control tests, non-compliance by contractor, health and safety issues,
etc. The ER can then give immediate directions to resolve such issues without delay.
3. Quality Control in Construction
The Quality Control system comprises standard procedures and methodologies designed to
ensure that the works are constructed to prescribed standards. The quality standards for
materials and workmanship are defined in the contract. Some procedures are described in
the contract, whilst others must be agreed between the Engineer and the Contractor prior to
the start of the works.
This section describes briefly the quality control requirements related to the major elements
of bridge construction. The contractual requirements are described in detail in the
appropriate clauses of the Technical Specifications. This QA Plan should not be used as a
substitute for the Technical Specifications, which are legally binding on both parties to the
contract.
3.1 General
The Contractor is responsible for achieving with the quality standards specified in the contract. The
Engineer is responsible for ensuring that the works are constructed to those standards.
6
The Certificate of Accreditation procedure may be developed further as part of DDC/DTO/RAIDP, Dhanusha.

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The main features of the Quality Control system are:
• The Contractor must obtain written approval from the Engineer before bringing materials to the
site. Approval will be based on testing of samples to demonstrate compliance with the
specification, together with approved storage and management procedures that ensure consistent
quality control will be maintained.
• Records must be kept of all materials brought to the site, together with corresponding tests to
confirm compliance with the specification, and the location of all materials incorporated into the
permanent works. Materials that fail to meet the specification requirements must be rejected by
the Engineer and removed from the site by the Contractor.
• The Contractor must obtain written approval from the Engineer before commencing each stage of
the works. Approval will be based upon satisfactory preparation for the works and quality control
tests on the preceding stage of works together with other requirements of the specification.
3.2 Materials storage and control on site
The Contractor’s site management arrangements will be submitted to the Engineer for approval prior
to the delivery of any materials to the site. The submission will include the site layout, handling
arrangements and a delivery and draw-down system to record the position of all materials in the final
works.
All materials brought to the site shall be kept free from contact with deleterious matter and shall be
deposited as near as possible to the site of mixing. Aggregates of different sizes and types shall be
stored in different hoppers or stockpile containers that are separated from each other by suitable
partitions. The type and size of all hoppers or containers shall be to the satisfaction of the Engineer.
The same arrangements apply equally to all materials brought to the site, including steel
reinforcement, prestressing cables, bearings, drainage fittings, etc.
The contractor shall at all times maintain on the site such minimum quantities of aggregates as agreed
with the Engineer to be necessary to ensure continuity of the work.
For larger projects cement should be stored in a purpose-built silo, whilst on smaller projects a
weatherproof go down with proper humidity control and water proofing arrangements may be
acceptable to the Engineer.
3.3 Temporary works
Typical temporary works for a bridge project may include diversion roads, diversion of utilities,
construction of culverts, and islands for well/bored pile foundations in the stream. In all cases the
contractor will submit designs and drawings for such works for formal approval by the Engineer,
including a maintenance schedule where appropriate. Record formats for

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all temporary works will be included in the contractor’s proposals. All temporary works must be
appropriate to the classification of the road, the traffic (motorized, non-motorized and pedestrian),
seasonal variations and the duration of the works. In the case of utilities crossing or located at the site
the appropriate owner must also give approval and where necessary undertake specific works.
3.4 Preparatory works
Preparatory works are an important aspect of quality control, eg excavation line, level and trimming,
formwork, reinforcement fixing, etc, and are frequently not given sufficient attention. It is essential
that the contractor notify the ER sufficiently in advance when preparatory works are ready for
inspection, and that the ER staff give written approval for the works to proceed (or alternatively clear
instructions on what remedial measures are required). Formats for different elements of the work are
included in Part 3.
3.5 Quality control tests of Materials
The Contractor is responsible for establishing a site laboratory for carrying out quality control tests on
his materials and workmanship to demonstrate compliance with the Specification. The laboratory must
be located within the limits of the Works area and be fully established before the Works commence.
Subject to the approval of the Engineer some tests may be carried out at an alternative laboratory
containing more complex testing equipment.
Prior to the commencement of the Works, tests must be carried out by an approved laboratory on
material samples (or mix designs) submitted to the Engineer for approval. No deliveries of materials
will be permitted until samples and a Materials Control System have been approved in writing7.
The Contractor must carry out regular routine testing in the site laboratory (supervised by the
Materials Engineer) on all materials delivered to the site. This will include additional tests on site on
those samples collected at random as part of the quality control check system.
3.6 Quality Control of Workmanship
Testing is required to confirm that approved construction materials are correctly mixed, placed and
compacted during the works. Preparatory works for concrete must be checked and approved at each
stage, eg reinforcement, formwork, mixing control. In the case of backfill behind abutments, each
layer must be tested and approved before the next is placed, since failure of an underlying layer will
result in rejection of the layers above it. All testing and approvals must be in writing using standard
forms contained Part 3.
3.7 Quality Control Tests
Quality Control tests are undertaken in three stages of the works:
7
To ensure that samples are correctly registered, tagged, tested and recorded for the separate contracts, and that test results
can be traced to materials deliveries to site

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• Materials prior to and during construction

• Quality of workmanship during construction
• finished works after construction
The Specification defines the quality control tests to be undertaken at each stage of the Works,
together with frequency and results that should be achieved. Works that are not covered by the General
Specification must be included in a Particular Specification, including tests, frequencies and results
for materials and workmanship. A summary of the tests undertaken should be maintained in a Record
Book, the format of which is contained in Part 3.
A detailed description of each test procedure is contained in the Standard Test Procedures
Where any test result fails to meet the requirements of the Specification the ER must be notified
immediately by telephone, and a copy of the failed test report dispatched to him if required. The ER
will direct the support staff on what action is required.
Copies of all test results, together with a summary sheet for each test, should be submitted to the ER
at the end of each week, or at such other frequency required by him.
Many of the tests may be undertaken on site using basic test equipment. Others will need to be carried
out in an off-site laboratory equipped with more complex machinery that has been approved by the
Engineer. In all cases the tests are to be undertaken by the Contractor at his own expense, the cost of
which is deemed to be included in the rate for the relevant work item.
When a contract requires specialized materials8 or components to be used and the Specification does
not require tests on those items the Engineer must ensure that the items proposed comply with the
Specification9.
The contractor must submit samples at the earliest opportunity to allow sufficient time for testing and
analysis results and to avoid delays to the construction programme.
3.8 Excavation
8
For example where thermoplastic paint is specified the contractor must use a proprietary brand of thermoplastic paint and
not simply road paint.
9
The contractor should supply manufacturer’s literature, specifications, factory tests, etc to demonstrate
compliance.
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Prior to any works on the site the contractor will prepare a pre-works survey for agreement and
approval by the engineer. The contractor shall also submit his proposed excavation plan and
programme for each excavation for approval by the Engineer. The plan shall include dimensions of the
excavation and the methods proposed for digging, support, de-watering, etc, together with a catalogue
system to record all details at agreed stages of the excavation. Photographs may be taken and materials
tests undertaken in locations directed by the Engineer.
3.9 Mixing of Materials
When on-site mixing is used the grading and proportioning of material fractions must be strictly
controlled to ensure that the final mix complies with the approved design. Method statements
(including proportioning, batching, mixing and testing) will be submitted to the ER for approval in
advance of the works. Under no circumstances should the proportioning of mixes be undertaken by
laborers taking materials from stockpiles on a random basis.
Where aggregate materials are mixed on site for concreting works, samples of the mix should be
taken in the presence of the ER’s support staff for workability, grading and strength tests in the site
laboratory. Whether mixed on-site or off-site, the ER’s support staff must take additional samples of
all concrete mixes for check testing at the approved laboratory.
3.10 Piling
The contractor shall submit a detailed piling programme to the Engineer for approval prior to bringing
any equipment and materials to the site. The details to be included will be discussed with the ER in
advance of the works.
3.11 False work
The contractor shall submit full design calculations and working drawings of all false work to the ER
for his consent prior to the start of the works using checklists agreed in advance. Such consent will
not relieve the contractor from his responsibility for the safety and integrity of the systems in question.
3.12 Concrete pour
The contractor shall submit method statements in advance of all concrete pours, regardless of size and
complexity. Immediately prior to the pour the contractor will submit a Pour Approval Request form to
the Engineer using the format contained in Part 3.
Particular attention should be given to the careful planning of concrete pours and ensuring that proper
construction joints are formed at the end of all pours. The incidence of “cold joints” or open-ended
pours on bridge construction is a cause of great concern. Concrete at these joints is weak and of low
density due to lack of vibration against a solid form. Such joints are also difficult to prepare for the
next pour, and this gives rise to the formation of a

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moisture path to reinforcement. It must therefore be agreed from the outset that cold joints of this
nature will not be permitted under any circumstances.
Another concern is the curing of freshly placed concrete. It is essential that proper curing is applied,
using hessian fabric (gunny bag) securely fixed on vertical faces and kept moist, or by water ponding
on horizontal slab surfaces. Failure to provide effective curing will result in shrinkage cracking
amongst other detrimental effects. This is a common problem, particularly in beams where curing is
frequently omitted altogether.
3.13 Approval of Preparatory Works
No new works shall be undertaken until the underlying or preceding works and the preparatory works
(eg setting out, formwork, steel fixing) have been approved in writing. Standard approval forms are
included as Part 3.
3.14 Non-compliance
Results of some tests may not be known for several days, eg concrete strength tests will not be known
until 7 and 28 days after placing. Where test results demonstrate that work does not comply with the
Specification the ER must be informed immediately. He may then instruct further intrusive and /or
non-destructive tests to be carried out on the completed works for the Engineer to decide whether to
accept or reject the works. The procedures for additional testing, at the contractor’s expense, must be
discussed in detail and agreed with the Engineer.
4. Document Control
An effective document control system is essential for effective management of the contract,
an integral part of which is the Quality Control of the Works. The PCU/PSC, RAIDP
monitoring of the management and supervision of the contract will examine and assess how
effectively the document control system is being implemented.
4.1 General
In order to comply with the Regulations it is essential that an effective document control system
be introduced from the start of the contract, and that all staff are aware of the system

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and its operation. Original contract documents must be safely stored at an appropriate location, with
working copies issued to other users in the system. Original correspondence will likewise be retained
in a designated location, with copies issued for action and information to other offices according to
need. The same applies to test certificates, delivery notes and other routine documentation.
The distribution of the main contract documents, correspondence, certificates and records is shown in
Figure 4.1. The establishment and operation of the Document Control System will be explained at
the Pre-Contract Workshop, at the end of which the supervision team will finalize their own system
for the contract. On completion of the contract the Employer’s Representative will ensure that all
documents are collected at one location, properly filed and stored as a comprehensive record of the
contract.
4.2 The Employer’s Representative
The Employer’s Representative will retain original copies of all contractual documents leading up to
and including award of contract. He must also be sent copies of all correspondence between the
Contractor and the Engineer that may give rise to a contractual claim.
4.3 The Engineer
The Engineer will be issued copies of contract documents and will retain original copies of contractual
correspondence between himself and the contractor. The ER may also send the Engineer copies of
other correspondence that he considers being important.
4.4 The Engineer’s Representative
In the absence of a site office provided under the contract the Engineer’s Representative must
maintain a separate documentation/filing system within his normal office for every contract under his
control. The system must be maintained within the office, documents must not be removed for any
reason, and files must be accessible to other authorized personnel in the absence of the ER. In the
event that the ER is transferred to another location during the course of a contract, he will prepare and
place on file a comprehensive handing-over file. This will include a list of all documents and files
handed over to the incoming ER, who will sign to acknowledge receipt (with a copy sent to the
Engineer), to ensure a seamless transfer of responsibilities.
4.5 Site Laboratory
All tests must be witnessed by the ER or support staff appointed by him for the purpose (the
‘Materials Engineer’). The tests required and their frequency are contained in the Specification.
Standard test result forms must be used, and these and the test report forms must be signed by the
person carrying out the test together with representatives of the Contractor and the Engineer.
Original copies of all results will be filed at the site laboratory. The ER staff may retain copies of any
results that they consider necessary.

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The Materials Engineer will submit to the ER a weekly summary of all tests carried out under the
contract. The ER will check the summary sheets and may request copies of individual results where
necessary in order to satisfy himself that the testing is satisfactory and has been correctly recorded and
filed at the site laboratory.
4.6 As Built Drawings
The contractor is responsible for preparing As Built Drawings for the contract. These must be prepared
and up-dated periodically as the works proceed and not left until the end of the contract. This is
especially important for works that will be covered up, embedded or otherwise hidden from view in
the final works. The ER should carry out a review of As Built Drawings on a monthly basis.
4.7 Site Diaries and Record Photographs
Site diaries and regular progress photographs are amongst the most important records to be
maintained during the execution of the contract. They are particularly important in case of
contractual disputes.

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Figure 4.1 - Document Control System original O

Standard formats are provided in Part 2 file copy C
Document Employer Engineer Engineer's Site Lab

Represent
Contract Documents :
Invitation for Contractor PQ O
PQ Criteria (approved) O
PQ List Tender O
Notice O
Tender Documents Tender O
Evaluation Report Notice of O C C
Award O C C
Signed Contract O C C
Contract Documents O C C C
Notice to Proceed O C C
Employer/Contractor correspondence O C C
Delegation of Powers to Engineer O C C
Engineer's Files :
Copies of surveys, design calcs, quants O C C
Contractor correspondence O C
Engineer/Employer correspondence O O C
Other correspondence O C
Contractor Programme & updates C O
VO's to contractor C O C
Site Instruction Register C O
Site Instructions from ER C O
Interim Payments certified by ER C O
Site Engineer's Files :
Site Diary O
Site Order Book O
Site Accident Record Book O
Contractor Progress Reports C O
Contractor Plant & Labour Returns O
ER Progress Reports C O
Pile Boring Record File O
Concrete Pour Record File O
Bending Schedule Approvals O
Copy Site Test Results C O
Off-site Test Results C O
Test Result Registers (by test) C O
Temporary Works Approvals C
Copy Approval to Commence C
Measurement Book O
Measurement Calculations - monthly O
Copy Interim Payment Applications C
Copy Interim Payment Certificates C

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5. Monitoring
This section describes briefly the monitoring function of the Bridge Construction and Maintenance
Circle. Detailed p r oc edu r es w i l l be pr es e nt ed at t h e Pr e - Construction Workshop and
hard copies issued to the supervision team.
5.1 Bridge Construction and Maintenance Circle
An essential purpose of the Bridge Construction and Maintenance Circle through each
division is to improve the construction of bridges and culverts on the DDC road network. A
major function of this Circle is to improve construction supervision of the Zonal Divisions
and consultants.
5.2 Contract Monitoring
The Bridge Construction and Maintenance Circle under the Bridge Management Wing are responsible
for the monitoring of the implementation of the Quality Assurance Plan for all bridges constructed by
Contractors.
5.3 Aspects of Monitoring
The key aspects of monitoring of bridge construction are:
• In order to be effective it must be undertaken by staff who are independent from the regular
contract management and supervision staff engaged at the site.
• It must be impartial and unbiased in its assessment. Monitoring should not be seen in a
negative way: it is not a policing operation; it does not seek to find fault, nor to apportion blame.
In order to be effective the monitoring must be carried out using an agreed set of criteria. The
PCU/PSC, RAIDP monitoring is based upon the Quality Assurance Plan for the particular
contract.
• It must be undertaken by suitably qualified and experienced staff that is familiar with the
works in question and aware of the difficult circumstances under which the works are being
implemented.
• It will be undertaken on a regular basis and reports will be produced and submitted to the
Zone and Wing Additional Chief Engineers. Recommendations will be given for overcoming
deficiencies where these are found and improving management where appropriate. Subsequent site
visits will verify if earlier recommendations have been implemented.

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• Inspections will be informative. The monitoring team will seek positive feedback and lesson
learning for the benefit of staff on similar contracts in other locations, and contribute to the overall
improvement of management and quality control.
• Visits will be supportive of the site staff. The team will assist in seeking solutions to any
difficulties found at the site or reported by field staff. Over time the Circle will develop as a
centre of excellence in bridge construction, and a focal point for raising concerns on issues
affecting contract implementation.
• Monitoring will contribute to higher order management by informing policy makers on

issues affecting bridge construction and maintenance
• The monitoring scheme and procedures will be subject to audit by an external office to check that
the system is being implemented effectively.
5.4 Outputs of Monitoring
The main outputs of the monitoring system are:
• It will verify whether prescribed management procedures are being implemented
• It will verify if technical standards are applied
• It will provide a regular check on the reported progress of the contract
• It will collect key information and data for use at Head Office and/or dissemination to other sites
and locations
• It will identify or respond to any needs for specialist support, and make necessary arrangements to
ensure that support is provided when required
• It will identify training needs at the field level for the continuing improvement of
management and supervision
• It will regularly report findings to the PCU/PSC, RAIDP.
• It will promote the adoption of consistent implementation procedures
5.5 What will monitoring achieve?
Monitoring will:
• Ensure that the site teams are achieving what they set out to do
• Ensure a consistent quality of output on all construction sites
• Learn lessons for continual improvement of working practices

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• Establish a line of communication for the exchange of lessons between field offices
• Identify areas of specialist support required
• Provide an opportunity for staff to inform management on specific bridge issues
• Help to identify where individuals may be experiencing difficulties provide support
• Allow Contractor to identify where standards require review and possible modification
6. Payment
Regular and timely payments to the contractor are essential for overall performance of the
contract and eventual delivery of the Works to the required quality, on time and within
budget.
The interim payment to the contractor should be made by the authorized officer for the particular
project (the Accountant) against the Interim Payment Certificate (IPC) 15 certified by the Engineer. The
payment procedure is described briefly as follows:
• Measurements of accepted works11 are recorded in the Site Measurement Book (MB) by the
ER (or the nominated Site Engineer)
• The contractor prepares his Monthly Statement based upon the MB, backed up by
bills/vouchers, and submits to the ER.
• The ER (or Site Engineer) prepares the IPC and verifies that the itemized quantities in the
Monthly Statement are in accordance with the MB. He enters the quantities, unit rates, item-
wise amounts and the IPC totals into the Central Monitoring System (CMS). At the same time
he enters a corresponding brief report on progress and quality on the CMS. He then attaches a
summary of the tests related to the works included in the IPC and confirms that the works
have been tested in accordance with the Specification, and have been accepted for payment.
The IPC is then forwarded to the Engineer.
• The Engineer certifies the IPC on CMS and makes his own report on progress and quality. He
then authorizes the Accountant to make payment to the contractor.
7. Settlement of Disputes and Problems that arise at the Site
11
For which tests have been submitted and approved, and records of the works have been made

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It is a fact that disputes and problems can arise on any construction contract. This is not
necessarily a reflection on the supervision team or any individual.
It is important that this is recognized from the start of the contract, and a broad mechanism is
established for the resolution and settlement of disputes effectively and without detriment to the
smooth running of the contract. Due the nature and range of disputes and problems that may arise it is
not practical to lay down strict procedures for dealing with every eventuality.
The majority of disputes and problems that arise on construction sites are attributable to one or more
of the following –
• Interpretation
• Communication
• Personal disagreement
A general approach to dispute resolution is illustrated in Figure 7.1 and this should be discussed and
developed during the Pre-Construction Workshop. The supervision team may decide to leave the
procedure in a general format, or alternatively develop particular aspects in greater detail. If the latter
action is decided then it may be appropriate to convene a follow up workshop possibly with additional
guidance and facilitation.
Figure 7.1 Dispute Resolution (How to resolve problems?)
Source Nature Incidence Referral Level Communication Timeframe
Is it - Is it - Is it - Is it - Is it - Is it -
Internal Official
Technical
team Contractor
Financial Public
Contractual
Personal
Site Team Line Manager
Site Team Line Manager Urgent - now
Verbal - direct Verbal - telephon e Written
Personal Senior Manager Senior Manager mmediate - today
Social Environmental Soon - one week
Later - one month
I Personal Higher Authority Personal
IDENTIFICATIONandACTION

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Figure 7.1 illustrates a sequential linear approach to problem solving and dispute resolution. It first
identifies the source and nature of the problem. If possible the site team should resolve the situation
themselves. Where this cannot be accomplished it will be necessary to refer to a others outside of the
immediate problem. In both cases t he m et hod of communication, or dealing with the issues, must
be agreed and a timeframe set for resolving the situation. The purpose of Figure 7.1 is to encourage a
focused approach to problem solving and dispute resolution, rather than letting a situation drift on and
thus risk time delays and contractual claims. Problems and disputes rarely resolve themselves.
Prompt action by both parties in the problem or dispute is essential to early resolution
In all problems and disputes it will be up to the team to follow through the process shown in Figure
7.1 to determine the appropriate course of action. In all cases it is preferable to deal with issues when
they arise and at the level at which they occur. When this is not possible it will be necessary to refer
the matter to the next appropriate level for guidance and advice.
Contractual disputes must always be dealt with in strict accordance with the Conditions of
Contract.
Notwithstanding the approach decided for a particular contract at the Pre-Construction Workshop, the
team should consult official as a matter of course when site disputes arise that may lead to
contractual claims. The official may be aware of similar instances on other contracts and be able offer
support directly, or alternatively seek the advice of individuals with specific experience in a
particular dispute. The purpose of this approach is to draw upon departmental experience as a whole to
support individual teams in the field.

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1. Introduction
1.1 General
Part 2 of the Quality Assurance Plan provides a series of outline templates that the supervision team
will customize to include the specific details of the contract in question.
The QA Plan will be developed and completed during the Pre-Construction Workshop when all of
the staff to be involved in the implementation of the construction works is present. Staff will have the
opportunity to raise issues and clarify any uncertainty over roles or ambiguity regarding
implementation arrangements. At the close of the Workshop there must be no doubt whatsoever over
the roles and responsibilities of each member of staff.
The QA Plan will be printed and distributed to each member of staff within 5 days of the Workshop.
This must be completed during the contract mobilization period when all staff will be equipped and
prepared before the preliminary construction activities commence.
Job Descriptions for each of the contractor positions are included in Annex A of Part 2.

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1.2 Contract Details
Zone
Circle
Division
Contract Name
Contract No
Tender No
Location
GPS Co-ordinates
Contractor
Award Date
Notice to Proceed
Duration
Contract Value

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1.3 Contract Staff

The designated staff will be confirmed at the QA Workshop.12 All designated staff will be notified in
writing and issued a specific Job Description for the contract13.
Designation Responsible Officer Name
Employer’s Representative
Engineer
Engineer’s Representative
Site Engineer
Assistant Engineer
Materials Engineer
Structural Engineer
Materials Inspector
Survey/Measurement Assistant
12
Part 1, Section 2.7
13
Annex A to this Contract QA Plan
Version 1 – March 2012 Page 22 of

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1.4 Contract Equipment and Facilities

All of the equipment, furniture and transport necessary for the effective supervision of the contract
will be identified in advance and confirmed during the QA Workshop 14. Items issued to individuals
will be covered in writing.
Item Location No Source Responsibility
Office
Telephone / Fax
Desk
Chair
Large Table
Cupboard
Chest of drawers
Computer
Printer
Photocopier
Mobile Phone
Motor cycle
14
Part 1, Section 2.7
Version 2 – March Page 23 of 30

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1.5 Contract Filing System

The contract filing comprises the following separate files. The system must be kept up to date at all
times.
File No Description Responsible Officer Location
1 Office Administration
2 Drawing Register
3 Contractor Correspondence
4 Consultant Correspondence
5 Other Correspondence
6 Minutes of Site Meetings
7 Contractor Submissions & Approvals
8 Materials
9 Programme
10 Progress Reports
11 Measurement & Payments
12 Calculations
13 Site Instructions
14 Variations
15 Land Acquisition & Resettlement
16 Public Liaison
17 Environmental Issues
Refer also to Part 1 – Document Control Figure 4.1

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1.6 Monitoring Procedures

The Management Plan, Volume 5, Bridge Management Wing Management Manual describes the
Monitoring of Bridge Construction Works by the Bridge Construction and Maintenance Circle. Flow
Chart 6.5 illustrates the procedures that will be followed.
The Monitoring Plan for this contract will be implemented as follows -
Division XX
Executive Engineer XXXXX XXXXX Tel -
(Monitoring Team Leader)
Monitoring Officer at Site XXXXX XXXXX Tel -
(Contact Person)
Frequency of Monitoring Visits 3-4 per year October, January, June
Reports Submitted to DDC/DTO/PCU/PSC, RAIDP
Copy to Contractor
Monitoring Tools Contract Documents
Programme
QA Plan
Monitoring Guidelines
It is important that Monitoring Reports are issued under cover of a letter. The Site Team must issue
the Report formally to the contractor.

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1.7 Pre-Construction QA Workshop

The QA Workshop is an essential feature of the QA Plan and is described in Part 1, Section
2.7. The Workshop will be arranged by contractor and official, if necessary.
Attendees Name Designation
Employer’s Representative
Engineer
Engineer’s Representative
Site Engineer
Materials Engineer
Structural Engineer
Assistant Engineer
Other
Agenda Action Note
Introductions
QA Plan Part 1 Presentation
Discussion & Issues Arising
QA Plan Part 2 Presentation
Discussion & Clarification
Preparation of Contract
Specific QA Plan
Accreditation Arrangements
Issue of QA Plan, Contract Minimum 7 days after During Mobilisation Period

Documents, QA Certificate workshop

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District Development
Committee
Rural Access Improvement and Decentralization Project
(RAIDP)
Dhanusha
Quality Assurance Programme
Certificate of Accreditation
Project ………………………
Location ………………………
Name ………………………
Designation ………………………
Project Position ………………………
Location of Assignment ………………………
This is to confirm that the above named officer, duly qualified and experienced, and having attended
the prescribed 2-day Workshop (not mandatory) has fulfilled the requirements of the Bridge
Construction and Maintenance Quality Assurance Programme and is hereby awarded this Certificate
of Accreditation.
The award of this Certificate confirms that the officer is QA approved to undertake the
duties of the specific position described above.
The following documents are issued with this Certificate and are to be retained by the member
of staff for the duration of the project assigned:
• QA Plan (specific to the contract) issued personally
• Personal set of contract documents to be held
• Detailed Job description
• Position
• Specific tasks (frequency, records, formats, documents, etc)
• Place and times of work
• Higher authority (reporting and assistance)
• Authority levels
• Reporting responsibilities
• Equipment assigned to the position
• Monitoring Plan for the contract
• Complaints procedures
• Disciplinary procedures
Awarded this …………. day of ……….………….. , …………… .
Signed Position
A Senior Officer duly authorized by the Quality Assurance Programme

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This Certificate remains valid for a period of contract from the date of issue.

Quality Assurance Plan for Bridge Construction Contracts
Specific Job
EMPLOYER’S
Approved:
ISSUE
This Job Description has been issued to the person named below –
Contract
Location
Position
Name of Post Holder
Designation
Office Location
Place of Work
Hours of W ork
Time or Visits at the worksite
Reporting Officer
GENERAL REQUIREMENTS:
The Post Holder must obtain formal approval from official to act as the Employer’s Representative and to be
named as such the Contract. In the event that the Post Holder ceases to act as the Employer’s Representative and
is replaced by another Officer during the term of the Contract, the Contractor must be formally notified of this in
writing by either the Post Holder or his immediate superior.
DUTIES & RESPONSIBILITIES:
In addition to the general responsibilities of the Post Holder, as specified in the Contract
Management Manuals, the specific duties relating to this position are detailed below:
1. To check and confirm that no other construction activities are proposed under any other
programme that would conflict with or undermine the economic justification for the Works.
2. To check and approve tender documents prepared for the W orks and in particular their compliance
with the current Public Procurement Regulation, Procedures, Standard Tender Documents and
Specifications adopted by contractor.
3. To check and ensure that a budget allocation has been made for the proposed works that
corresponds to the Engineer’s Estimate and that any land acquisition or removal of encroachments
has been completed prior to floating a tender for the Works.
Iss ue 1 March Page 1 of

Specific Job
EMPLOYER’S
Approved:
4. To check and ensure that the information contained in any advertisement for an Invitation to Tender
corresponds exactly with the Instructions to Tenderers within the Tender Documents, that the tender
period is not less than the minimum period required under the Procurement Regulations for the type of
tender, and to then authorize the floating of the Tender.
5. In conjunction with the Engineer for the Contract to attend any pre-tender meeting with Tenderers and
to ensure that all tenderers are formally notified in writing of any queries raised, either at the meeting or
separately, and responses given.
6. To ensure that both the opening and evaluation of tenders are undertaken in accordance with the Public
Procurement Regulations, and that the Tender Evaluation Report with a recommendation for the award
of the Contract is submitted to the approving authority having the delegated financial power to award
the contract.
7. To issue the Notice of Award to the successful tenderer and subsequently to sign the Contract on behalf
of official.
8. Throughout the Contract to undertake the duties and responsibilities assigned to the Employer under the
Conditions of Contract.
SPECIFIC RESPONSIBILITIES:
1. To be completed during the QA W orkshop 2.

3.
REPORTING RESPONSIBILITIES:

3.
Iss ue March Page 2 of

Specific Job
THE
Approved:
ISSUE
Contract
Location
Position
Name of Post Holder
Designation
Office Location
Place of Work
Hours of W ork
Reporting Officer
The Post Holder must have formal approval from the Employer’s Representative to act as the Engineer and be
named as such the Contract. In the event that the Post Holder ceases to act as the Engineer and is replaced by
another Officer during the term of the Contract, the Contractor must be formally notified of this in writing
by either the Post Holder or the Employer’s Representative.
The overall duties and responsibilities of the Engineer are defined in the Contract. The Engineer usually
delegates some or all of his duties and responsibilities to his representative (‘The Engineer’s Representative’)
named in the Contract. On the assumption that there is an Engineer’s Representative the following duties and
responsibilities should not be delegated and should be retained by the Engineer:
1. Issuing the formal notice to the Contractor to commence with the Works
2. Notifying the Contractor of the duties and responsibilities that he is delegating to his Representative
(or conversely the duties and responsibilities that he is not delegating)
3. Notifying the Contractor of any replacement Engineer’s Representative
4. Approving Variation Orders that have financial implications
5. Approving significant variations in the quantities

Specific Job
THE
Approved:
6. Approving sub- contracting any part of the W orks

7. Approving extensions of time
8. Approval to the use of dayworks, provisional sums and contingencies
9. Withdrawing approval to the Contractor’s Representative
10. Issuing Taking -Over Certificates for the whole or parts of the W orks
11. Authorization of payment certificates
12. Issuance of Defects Liability Certificate
13. Issuance of Completion Certificate
14. Providing decisions in relation to Contractual matters between the Employer and the Contractor
15. The full duties of the Engineer under the Contract in the event of disputes, frustration, termination,
adjudication and arbitration.

3.

3.
In the event that there is no Engineer’s Representative for the Contract, in addition to the foregoing the Engineer
will be responsible for the duties and responsibilities of the Engineer’s Representative.

Specific Job
ENGINEER’S
Approved:
ISSUE
Contract
Location
Position
Name of Post Holder
Designation
Office Location
Place of Work
Hours of W ork
Reporting Officer
The Engineer’s Representative must be named as such the Contract. In the event that the Engineer’s
Representative is replaced by another Officer during the term of the Contract, the Contractor must be formally
notified of this in writing by the Engineer for the Contract.
In addition to the general responsibilities of the Engineer under the Contract that have been delegated by the
Engineer to the Engineer’s Representative, the specific duties relating to this position are detailed below:
1. Prepare a Quality Assurance Plan for the W orks incorporating, amongst other things, procedures for
document control and quality control.
2. Review the Contractor’s work programme and method statements, and instruct the Contractor to make
necessary adjustments if delays occur in particular work items that could result in an overall delay to the
completion of the Works
3. Ensure that the quality of materials brought to the works site and quality of construction by the
Contractor comply with the requirements of the Contract
4. Where required by the Contract, ensure that the Contractor establishes a site laboratory for the Works
with correctly calibrated testing equipment and qualified staff to undertake the specified quality control
tests on his materials and workmanship at the required frequency

Specific Job
ENGINEER’S
Approved:
5. Ensure that all such tests are witnessed and certified by himself or support staff who are assisting him,
and that proper records of these tests are maintained by the Contractor in the site laboratory in
accordance with the Quality Assurance Plan
6. Reject any materials or workmanship by the Contractor that do not meet the requirements of the
Contract
7. Issue instructions, directions and orders to the Contractor on behalf of the Engineer
8. Prepare Variation Orders to the Contract for issue by the Engineer or the Employer
9. Advise the Engineer on all issues affecting the Contractor’s approved programme, rate of progress and
performance during construction
10. Prepare evaluations and recommendations to the Engineer with respect to any Claims or requests for
extension of time submitted by the Contractor
11. Ensure that the Contractor complies with the requirements of the Contract in relation to the health and
safety of his workforce and the public, together with mitigation of social and environmental impacts
caused by the Works
12. Undertake monthly measurement of the value of the Works completed by the Contractor and to prepare
Interim and Final payment certificates for payment by the Employer
13. Check and approve the setting out of the Works by the Contractor, including survey stations and bench
marks
14. Supervise, monitor and direct supervision staff under his control in the inspection and quality control of
the W orks carried out by the Contractor.
15. Maintain an up-to-date daily Contract Diary and daily records of plant, labour and equipment provided by
the Contractor.
16. Maintain an up-to date filing system for drawings, correspondence, instructions, reports, statements,
measurements, variations, claims and any other Contract documentation in accordance with the Quality
Assurance Plan.
17. Receive, check, approve and forward to the Engineer the Contractor’s monthly statement for payment.
18. Organize, supervise and monitor the preparation of ‘as-built’ drawings of the completed sections of he
W orks and agree the completed record drawings with the Contractor

3.

3.

Specific Job
ENGINEER’S
Approved:
On almost every Contract the Engineer’s Representative will be supported by more junior staff who will be
responsible for assisting the Engineer’s Representative in carrying out his duties and responsibilities. Where such
staff are not assigned, and in any event, the Engineer’s Representative assumes full responsibility for the activities
undertaken by them as detailed in their Job Descriptions.

Specific Job
MATERIALS
Approved:
ISSUE
Contract
Location
Position
Name of Post Holder
Designation
Office Location
Place of Work
Hours of W ork
Reporting Officer
The Post Holder(s) will be assigned on a full or part time basis to assist the Engineer’s Representative (ER) in the
supervision of the quality control testing of materials and workmanship by the Contractor. The Post Holder(s)
should have adequate previous relevant experience in laboratory and field quality control tests.
1. If required by the Contract, check that the Contractor has provided a site laboratory in accordance with
the Specification, and that it is equipped with adequate materials testing equipment that is correctly
calibrated
2. Check that the Contractor has appropriate test forms for each test procedure required under the Contract
and that the Contractor has appropriate record keeping procedures that comply with the Quality
Assurance Plan
3. Throughout the Contract ensure that the Contractor uses the correct test procedure forms and complies
with the document control procedures required under the Quality Assurance Plan.
4. Ensure that all materials delivered to site, or manufactured on site, comply with the quality standards
required by the Contract, through inspection of manufacturer’s certificates supported by supervision of
on-site testing or organization of specialist testing in an approved laboratory.

Specific Job
MATERIALS
Approved:
5. Ensure that all tests undertaken by the Contractor are carried out in accordance with the RHD Standard
Test Procedures and to the required frequency called for in Contract Specifications
6. Witness and certify all laboratory and field tests undertaken by the Contractor and immediately notify the
ER of any test results that fail to meet the requirements of the Contract.
7. Ensure that the properties of pavement and embankment materials after placement are in accordance with
the quality standards required by the Contract through supervision of laboratory testing and insitu
testing programmes.
8. Ensure that all concrete materials are tested in accordance with the requirements of the Contract.
9. Maintain a daily record of materials delivered to site and both laboratory and in-situ tests carried out
together with the results (pass/fail) obtained.
10. Prepare and maintain a monthly summary of the quality control tests (based on the daily records) with
the action taken in respect of those tests that failed to meet the requirements of the Contract

3.

3.

Specific Job
STRUCTURAL
Approved:
ISSUE
Contract
Location
Position
Name of Post Holder
Designation
Office Location
Place of Work
Hours of W ork
Reporting Officer
The Post Holder may be assigned on a full or part time basis to assist the Engineer’s Representative on
contract that includes bridges or culverts. The Post Holder should have sufficient previous relevant experience in
the design and construction of similar structures to be able to perform his duties with only limited direction and
supervision from the Engineer’s Representative (ER).
1. To assist the ER in the supervision of construction of structures and to immediately notify the ER of
any departures by the Contractor from the requirements of the Contract.
2. Review proposed designs and layouts for culverts and bridges and advise the ER on the need for any
changes or additional detailing
3. Review and recommend for approval by the ER the Contractor’s proposals for borehole ground
investigations at the site of new bridges
4. W ork with the Contractor to finalize the detailed design of bridges, including the design of sub- structures
based on the findings of the site investigation
5. Check and recommend for approval by the ER the Contractor’s shop drawings for culvert and bridge
construction

Specific Job
STRUCTURAL
Approved:
6. Check and recommend for approval by the ER the Contractor’s proposals for concrete mix designs
7. Review the Contractor’s proposals for pile testing and monitor the supervision of field trials
8. Check and verify for compliance with the Contract the Contractor’s field and off-site laboratory test
records on cement, aggregate, sand, rebar, and any other materials to be used by the Contractor for the
construction of structures.
9. Check and verify the Contractor’s setting out for structures including formwork, spacers, box outs, ducts,
chamfers, etc
10. Check and verify the Contractor’s placement of reinforcement including bar sizes, type, spacing, lap
lengths, ties, cover and rigidity.
11. Check and verify that the Contractor mixes concrete in accordance with the approved mix design and
that slump tests are taken at the correct frequency and that these meet the requirements of the Contract.
12. Ensure that cube / cylinder samples are taken at the correct frequency and that off-site laboratory tests
demonstrate that these meet the requirements of the Contract.
13. Ensure that the placing, vibration and surface finish of concrete, together with all ducts, pipes, parapets,
drains, joints or any other works forming part of the finished structure meet the requirements of the
Contract
14. Review and recommend for approval by the ER the ‘as-built’ drawings of completed structures prepared
by the Contractor

3.

3.

Development
1. Introduction
Part 3 of the Quality Assurance Plan contains a series of page templates to be used in the Site Record
Books. These books are the means through which the QA Plan is physically implemented. They are
also an important feature of the Monitoring Inspections that will be conducted by the Bridge
Construction and Maintenance Circle.
The Site Record Books are in 3 categories –
1. Summary of Testing
3. Records
The formats for the Record Books for construction supervision have been prepared by Contractor and
approved by the o f f i c i al , Bridge Management Wing20. Each template includes sample entries for
illustration.
The number and scope of the Books will be expanded in due course, as site staff becomes familiar
with the implementation of the QA Plan and the associated monitoring visits by the office
representative. The actual formats for the additional books and forms will be developed by official
and agreed with site staff in order to ensure that particular needs are met.
The contractor will provide suitable books and ensure that they are suitably headed up. Books must be
of good quality with stitched and glued spines, and should have sequentially numbered pages (either
as purchased or added afterwards). Pages must not be removed from the books during the progress of
the works. All books must be kept at the site at all times.
A list of the Record Books currently in use is included in Table 1.
Table 1 Site Record Books
Book No Description
Testing T-1 Materials Delivery & Testing
T-1.1 Coarse Aggregate T-
1.2 Fine Aggregate
T-1.3 Cement
T-1.4 Reinforcement
T-1.5 Water
T-2 Concrete Compressive Strength Register
Inspection/Approval A-1 Commence Installation of Reinforcement & Concrete Pour for
Bored Piles
A-2 Formwork Inspection Check List
20
RHD Management Manual, Volume 5 Bridge Management Wing, Operational Procedure OP/BCM/2.1

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A-3 Reinforcement Inspection Check List

Record R-1 Slump Diary
R-2 Equipment Calibration & Service Record
R-3 Concrete Pour Record
R-4 Finished Concrete Inspection
R-5 Correspondence Register
R-6 As Built Drawings Register
2. Testing
Standard testing requirements are contained in the appropriate clauses of the Specification. The
methodology for conducting each test is described in detail in the Standard Test Procedures (STP),
together with standard test sheets and reporting formats. The Site Record Books do not replace the
standard sheets, rather they simply record a summary of the each particular test in the order in which
they are undertaken. The actual test sheets and corresponding reports should be maintained at the site
laboratory for record purposes.
A summary of the basic testing requirements for materials is given in Table 2. There are additional
requirements for specific items and components and these are prescribed in the appropriate clauses of
the Specification
Table 2 Testing Requirements for Materials for use in Structures
Material Test STP Ref Result Frequency

Cement Fineness DoLIDAR AASHTO M 85 1 per delivery batch
Setting Time DoLIDAR Ditto
Compress Strength DoLIDAR Ditto
Coarse Aggreg Flakiness DoLIDAR < 30 Daily or as directed
ACV DoLIDAR < 30%
SG & Absorption DoLIDAR As per Spec
10% Fines DoLIDAR > 150kN
Grading As per Spec
Fine Aggreg Organic Content DoLIDAR As per Spec
SG & Absorption DoLIDAR As per Spec
Grading As per Spec
Water AASHTO T 26 As per Spec
Concrete Slump DoLIDAR 1 per 25m3
Compress Strength DoLIDAR As per Spec 3 tests per casting or every
15m3
Reinforcement General DoLIDAR As per Spec 2 samples each batch
Tension DoLIDAR As per Spec
Bending DoLIDAR As per Spec
Pile Integrity 1 each pile

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The Materials Delivery & Testing Record Book contains separate sections for each material used in
the works. The purpose of the book is to provide a summary of testing that relates delivery notes to
compliance tests in a format that can be followed though easily and effectively. It provides a running
summary of test results and a cumulative record of testing frequencies.
The book should be completed by the contractor and countersigned/approved by the appropriate
representative.
The Approval Books contain a series of headings that will guide the contractor and the official team
through the process of preparation, inspection and approval. They are effectively a site checklist and a
record of the process.
The contractor should complete the entry, with the date and signature. The book is then submitted to
the official representative for checking. If he is satisfied that the works may begin then he signs the
book accordingly. In the event that some items are not satisfactory the official representative should
indicate this in the appropriate column and then give a corresponding instruction in the Site
Order Book describing the location and nature of the corrective works that are necessary. When the
corrections have been made the contractor re-submits the book for approval. If the preparation is
satisfactory the official representative will sign accordingly.
4. Records
The Record Books are similar to the Approval Books. The detailed entry is completed by the
contractor, and this is endorsed/approved by the official representative. If he disagrees with the
contractors assessment he should make a corresponding entry in the Site Order Book.
Version 2 March 2012 Page 30 of 30

Book No Materials Delivery &
Separate sections for each material
T-1.1 Coarse Aggregate
Date Chalan No Quantity Size / Unit Cumulative Test Test No Result Frequency Signature Designation
Brand Pass / Fail Specified Actual
Gradation
Flakiness / Elongation
QAP Part 3 site books - FINAL.xls T-1

T-1.2 Fine Aggregate
SG & Absorption

T-1.3 Cement
Setting Time
Compressive Strength

T-1.4 Reinforcement
Tension

T-1.5 Water
Chemical Analysis

Book No Concrete Compressive Strength
Date Location Date Cast Mix Type Sample Date Test Age Specified Tested Density Notes Signature Designation
Ref No Crushed Sheet No days Strength Strength
MPa MPa kg/m3
QAP Part 3 site books - FINAL.xls T-2 Conc compr strength

Book No Approval to Commence Installation of Reinforcement & Concrete Pour for Bored
Separate line per pour
Date Location Length Reinforcement Boring Casing

Design Actual Sizes Spacing Laps Tieing Cover Dia Base Approved Length
Clean Perm Temp
Materials Plant Labour Safety Lighting Ready for Inspection Approved to Proceed
Approved Approved Approved Approved Approved Signed Time Signed Time
No
42 No 7:35 AM Red entries are by Contractor Blue

9:50 AM
entries are by official
See separate book no R-3 for concrete pour record
QAP Part 3 site books - FINAL.xls A-1 Pile

Book No Formwork Inspection Check
Red entries are by Contractor
Separate line per pour Blue entries are by official
Date Location Details Formwork Falsework Face Boarding Tie Rods Reinforce Box-outs
Align Dimension Sizes Quality Thickness Joints Flatness Sizes Spacing Tight Spacers
04-Nov-05 Pier 04 level 2.50

NOT OK NOT OK NOT OK NOT OK
Prestressing Chamfers Formwork Release Construct Access Workspace Ready for Inspection Approved to Proceed
Alignment Duct/Cable Anchorage Clean Oil Joint Safe Signed Time Signed Time
7:35 AM
NOT OK 9:15 AM
11:05 11:35 AM
QAP Part 3 site books - FINAL.xls A-2

Book No Reinforcement Inspection Check
Date Location Length Reinforcement Ready for Inspection Approved to Proceed

Clean Sizes Spacing Laps Cover Tieing Rigid Signed Time Signed Time
QAP Part 3 site books - FINAL.xls A-3

Book No Slump
Separate page per pour
Date Location Details Quantity Mix Type Slump Time Slump Result Comments Signature Designation
m3 Specified Actual Pass / Fail
mm mm
QAP Part 3 site books - FINAL.xls R-1 Slump

Book No R-2 Equipment Calibration & Service Record
Separate page per item
Date Item Details Identification Last Calibration Load Result Next Notes Signature
Calibration Authority Specified Actual Pass / Fail Calibration
/ Service / Service
QAP Part 3 site books - FINAL.xls R-2 Equipment

Book No R-3 Concrete Pour Record
Date Location Details Formwork Reinforce Volume Mix Type Start Samples Samples
Form A-2 Form A-3 Time Times Ref
Approved Approved m3
Any problems ? (make separate detail report) End Notes Contractors RHD
Seggregation Pour in Vibration Cold Formwork Slurry Equipment Other Time Rep Rep
Layers Satisfactory Joints Movement Loss Failure Problems
see separate diary for slump
QAP Part 3 site books - FINAL.xls R-3 Conc

Book No R-4 Finished Concrete Inspection
Date Location Details Pour Dimension Observations - Any problems ? (make separate detail report) Notes Contractors RHD
Date Check Honeycomb Air Voids Cracking Formwork Surface Other Rep Rep
Movement Finish
QAP Part 3 site books - FINAL.xls R-4 Finished co

Book No R-5 Correspondence Register
1. Incoming
ER Direction & Date

Sl No Date In From Subject Action Action by Action
Time Required complete
2. Outgoing
Sl No Date In To Ref Subject Note
QAP Part 3 site books - FINAL.xls R-5 Correspondence

Book No R-6 As Built Drawings Register
one page per drawing
Drwg No Title Pile Cap General Arrangement
Date Reference Record added By
Drwg No Title East Abutment
Date Reference Record added By
QAP Part 3 site books - FINAL.xls R-6 As blt

Quality - Assurance - Plan - QAP - For Concrete Works

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Government of Nepal

Ministry of Local Development

Foreword to the Bridges Quality Assurance Plan

2. Management and Organization

3. Quality Control in Construction

3.13 Approval of Preparatory Works

PART 2 CONTRACT QA PLAN

Annex A Job Descriptions

PART 3 QUALITY ASSURANCE FORMATS

3. Inspection & Approval to Proceed

1.1 Quality Control is not Quality Assurance

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QC and QA cannot be separated. The two systems must be implemented together.

1.2 What will QA achieve?

1.3 The QA Plan is in 3 sections

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1.4 Implementation of the QA Plan

1.5 Construction Monitoring

1.6 Additional Sections

Social and Gender Issues

Health, Safety and Welfare

2. Management and Organization

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2.1 Parties to the contract

There are three entities defined in the contract2 :

The Employer is:

2.4 Engineer’s Representative (ER)

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2.5 Support staff

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2.7 Quality Accreditation

3. Quality Control in Construction

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The main features of the Quality Control system are:

3.2 Materials storage and control on site

3.3 Temporary works

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3.4 Preparatory works

3.5 Quality control tests of Materials

3.6 Quality Control of Workmanship

3.7 Quality Control Tests

Quality Control tests are undertaken in three stages of the works:

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• Materials prior to and during construction

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3.9 Mixing of Materials

3.11 False work

3.12 Concrete pour

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3.13 Approval of Preparatory Works

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4.2 The Employer’s Representative

4.3 The Engineer

4.4 The Engineer’s Representative

4.5 Site Laboratory

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4.6 As Built Drawings

4.7 Site Diaries and Record Photographs

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Figure 4.1 - Document Control System original O

Document Employer Engineer Engineer's Site Lab

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5.1 Bridge Construction and Maintenance Circle