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A SHGHAL - P UBLIC W ORKS A UTHORITY QA/QC P AVEMENT C ONSULTANCY S
A SHGHAL - P UBLIC W ORKS A UTHORITY QA/QC P AVEMENT C ONSULTANCY S

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

APPENDIX A: COLLECTION OF PROJECT INFORMATION

OPERATING PROCEDURE OP - 01

Collection of Project Information

Revision Number:

Prepared By:

Position:

5

Mohammed Anshasi

Quality Auditor

Issue Date:

Reviewed By:

Position:

23/10/2014

Alfredo Marques Mohammed Anshasi Davide Lioi

Quality Expert Assistant Quality Auditor Pavement Expert Assistant

Effective Date:

Approved By:

Position:

23/10/2014

Hussain Bahia

Leading Pavement Expert

Revision History:

Revision

Revision

Description of changes

Requested by

Number

Date

 

0 13-02-2014

Initial Release

Leading Pavement Expert

 

1 17-02-2014

Minor Changes

Leading Pavement Expert

 

2 09-06-2014

Changes in Terms, Definitions and Acronyms and Responsibilities

Leading Pavement Expert

 

3 13-09-2014

Expanding the list of required project information

Leading Pavement Expert

 

4 19-10-2014

Revise the list of required project information

Leading Pavement Expert

 

5 23-10-2014

Revise the list of required project information and the schedule templates/ID Coding Updating

Leading Pavement Expert

APPENDIX A: OPERATING PROCEDURE OP01 REV5 COLLECTION OF PROJECT INFORMATION

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A SHGHAL - P UBLIC W ORKS A UTHORITY QA/QC P AVEMENT C ONSULTANCY S
A SHGHAL - P UBLIC W ORKS A UTHORITY QA/QC P AVEMENT C ONSULTANCY S

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

TABLE OF CONTENTS

APPENDIX A: COLLECTION OF PROJECT INFORMATION

A-1

A.1

POLICY

A-3

A.2

SCOPE / FIELD OF APPLICATION

A-3

A.3

TERMS, DEFINITIONS AND ACRONYMS

A-3

A.4

RESPONSIBILITIES

A-5

A.5

PROCEDURE

A-5

A.5.1

INFORMATION REQUIRED FOR A NEW PROJECT

A-5

A.5.2

NAME & CONTACT DETAILS REQUIREMENT

A-5

A.5.3

INITIAL MEETING AND PROJECT INFORMATION REQUEST

A-6

A.5.4

AP BRIEFING AND PROJECT AUDIT PROPOSAL

A-8

A.5.5

PROJECT CONSTRUCTION INFORMATION REQUEST

A-8

A.5.6

INFORMATION TRANSMISSION

A-9

A.5.7

PROCEDURE EFFECTIVENESS CRITERIA

A-9

A.5.8

FORMS/ RECORDS

A-10

APPENDIX A: OPERATING PROCEDURE OP01 REV5 COLLECTION OF PROJECT INFORMATION

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A SHGHAL - P UBLIC W ORKS A UTHORITY QA/QC P AVEMENT C ONSULTANCY S

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

A.1

POLICY

Project Information that will be collected following this procedure will be accurate, reliable and always up to date, according to the PWA official contractual documents for the project.

A.2

SCOPE / FIELD OF APPLICATION

The scope of this activity is to obtain all relevant project information for projects audited by ANAS.

This procedure outlines the set of documents that are required by ANAS at the commencement and during audit activities on projects. It also outlines the expected channels of communication to keep project information updated.

A.3

TERMS, DEFINITIONS AND ACRONYMS

Auditee: Organization, area, task, function, or department being audited.

Auditor: Individual who carries out an audit. A person qualified and authorized to perform all or part of an audit by way of training and experience.

Key Supply Chain Partners (KSCP): The entities that affect directly or indirectly, inside or outside Qatar, the construction of roads for the PWA contracts.

Leading Pavement Expert (LPE): ANAS Resource responsible for directing the technical activities of the project, responsible for the development of technical plans, preparation of technical reports, briefs and circulars and make technical presentations to the PWA and other stakeholders.

Quality Auditor: ANAS Resource, responsible for the overall management and monitoring of the information, performed under progress or planned for the future, for a specific project.

Programme Lead: The PWA Resource responsible for the management and supervision of the QA/QC Pavement Consultancy Services Contract.

QA/QC Project: The Quality Assurance / Quality Control Pavement Consultancy Services project, awarded to ANAS S.p.A.

Quality Management System (QMS): Ordered, well-documented quality system, the primary goal of which is a quality product / service.

Task 3 Leader: ANAS Resource responsible for the overall management of the Task 3 Auditing activities both internally (planning, executing, monitoring and controlling and reporting) and externally (communicating with the PWA and Key Supply Chain Partners of the roads construction industry).

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A SHGHAL - P UBLIC W ORKS A UTHORITY QA/QC P AVEMENT C ONSULTANCY S

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Task 3 Audit Planner (AP): Activity performed by a nominated ANAS Resource in the Task 3 team, responsible for the elaboration, continuous update, monitoring and controlling of the planning of Task 3 auditing activities.

ANAS: ANAS S.p.A Qatar Branch ANCR: Audit Non Conformance Report AP: Task 3 Audit Planner CAR: Corrective Action Report CP: Construction Practices CPAP: Construction Practices Audit Plan DC: Document Controller GEC: General Engineering Consultant KSCP: Key Supply Chain Partners ITP: Inspection Testing Plan LA: Lead Auditor LPE: Leading Pavement Expert PAP: Project Auditing Proposal PL: Programme Lead PWA: Public Work Authority PMC: Programme Management Consultant PQMA: Project Quality Management Audit QA/QC Project: QA/QC Pavement Consultant Services Project QM: ANAS S.p.A. Qatar Branch Quality System Manager QMS: Quality Management System RE: Resident Engineer SC: Supervision Consultant WBS: Work Breakdown Structure

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

A.4

RESPONSIBILITIES

The Audit Planner (AP) reports to the Task 3 Leader or Leading Pavement Expert (LPE) and is responsible for:

Planning of all necessary activities in order to obtain timely and accurate project information for each PWA project to be audited by ANAS;

Communicating with the PWA and the KSCPs (as necessary) in order to request and receive the project information;

Delivering all the project information to the Document Controller (DC), with clear instructions regarding the storage, display and distribution;

Evaluating the effectiveness of the project information regarding the planning and executing of the auditing activities;

Implementation this procedure; and

Providing feedback to the QM for continuous improvement.

The Task 3 Leader reports to LPE and is responsible for:

Addressing all the issues / problems that might arise while the project information is being collected; and

Organizing relevant kick-off meetings with the KSCPs of each project (participants, timing etc.).

A.5

A.5.1

PROCEDURE

INFORMATION REQUIRED FOR A NEW PROJECT

The PWA will request ANAS to consider a new project for auditing. ANAS will review the request and compare to the criteria it established for projects that need to be audited. ANAS will respond to PWA with the recommendations to audit or not audit the specific project. If the Project to be audited by ANAS is approved by PWA for auditing, PWA sends a formal request to ANAS including the expected starting date for the project. The PWA instructions can be delivered to ANAS either by an official letter or by e-mail. ANAS proceeds to collect all relevant Project Information, as listed below.

A.5.2

NAME & CONTACT DETAILS REQUIREMENT

ANAS is to collect the names and contact details of all relevant parties involved within the Project contract:

PWA Project Manager;

PMC Project Manager;

Supervision Consultant (SC) / General Engineering consultant (GEC):

o

Senior Resident Engineer;

o

Road Resident Engineer;

o

Material Engineer;

o

Site Road Inspector;

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

o Quality Manager;

Construction Contractor:

o

Project Manager;

o

Construction Manager;

o

Quality Manager

A.5.3

INITIAL MEETING AND PROJECT INFORMATION REQUEST

Within one week of receiving the request from PWA for auditing a project, ANAS responsible Engineer/Auditor schedules (AP) an initial meeting with PWA and PMC/SC Project Managers, collecting / requiring the following information:

1. Project contractual information:

1.1. GEC contract technical submission;

1.2. Contractor Project technical submission;

1.3. Quality Manual (Quality Assurance and Quality Control plans) for:

1.3.1. PMC/GEC/SC;

1.3.2. Contractor;

1.3.3. Subcontractor/Supplier;

1.3.4. Third Party Laboratory.

2. General Project information

2.1 Brief project description:

2.1.1. Project location “GIS Map”;

2.1.2. General drawing layout with Chainages;

2.1.3. Road layers cross sections;

2.1.4. Interchanges / bridges, carriageway type, number of lanes;

2.1.5. Site accesses layout and traffic management plan if applicable.

2.2. Project Contact details

2.2.1 PMC (Project Manager)

2.2.2

SC (Senior RE, RE Roads, Senior Materials Engineer, Inspectors)

2.2.3

Contractor (Project Manager, QA/QC Manager, Plant Manager)

2.3.

Project Detailed Design information;

2.3.1. Pavement design report

2.3.2. Materials and Mix design submittals as applicable:

2.3.2.1. Unbound Materials;

2.3.2.2. Cement Bound Materials;

2.3.2.3. Asphalt Courses.

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

2.4. Project Planning and Scheduling

2.4.1. Project baseline Schedule, to include (WBS, Project calendars and work periods, activities definitions, duration and sequencing);

2.4.2. Three months look-ahead of pavement activities schedule (last Thursday of the Month on or before 2:00pm);

2.4.3. Biweekly look-ahead of pavement activities schedule (every Thursday on or before 2:00pm);

2.4.4. Daily notification of pavement activities (one day before the planned activity on or before 2:00pm).

2.5. Project Quantities and Physical Progress

2.5.1. Quantities’ Calculations (For all Different Pavement Structures in the Project)

2.5.2. Areas calculations according to WBS;

2.5.3. Volumes calculations for each layer according to design drawing with related cross section;

2.5.4. Tonnage calculations for each layer according to design drawing with related cross section;

2.5.5. Biweekly Physical progress for each pavement layer (every Thursday on or before 2:00pm);

2.5.6. Daily progress and activities completed (daily on or before 2:00pm).

2.6. Material Sources and Suppliers:

2.6.1. Subgrade Suppliers and Crusher;

2.6.2. Aggregate bases Suppliers, Crusher and Wet Mix Plant;

2.6.3. CBM Suppliers, Crusher and Plant/s;

2.6.4. Asphalt Mixtures aggregates source, binder source, PMB Suppliers, Plant/s.

2.7. Pavement, material production, construction and quality control documents

2.7.1. Stockpile management plan

2.7.2. Approved Method Statement for pavement layers production and construction;

2.7.3. Approved ITP’s for pavement layers;

3. Materials’ Testing Laboratory and Contacts:

3.1. Contact details of the third party laboratory (legal name, Laboratory Manager Name).

4. Materials Specification Requirements (QCS 2010, PWA Guides, etc.).

5. Materials testing results (Summary Logs) for all pavement layers from Third-Party Laboratories to be sent on Biweekly basis (every other Thursday on or before

2:00pm).

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

6. Any Change and/or new instructions regarding the specification requirements officially given to the contractor shall also be provided to ANAS within Two working days.

The above Project Information shall be provided to ANAS within one week from initial meeting with PWA/PMC Project Managers or as noted for periodical information requested during project execution phase, i.e. look-ahead schedules, physical progress and summary logs of material testing results.

Once the documents requested are obtained, the AP will check the information against the “Project Initial Information Checklist” OP-01-F01. In case information is not complete, the check list with the missing documents highlighted will be issued to the PWA/PMC Project Managers.

A.5.4

AP BRIEFING AND PROJECT AUDIT PROPOSAL

Within one week of receiving the required information, a specific briefing will be given by the AP to ANAS Project Manager and LPE. AP is also required to prepare and present to PWA the Project Auditing Proposal (PAP).

PWA will review the PAP and give feedback for approval or rejection to ANAS within one week of receipt of the PAP.

A.5.5

PROJECT CONSTRUCTION INFORMATION REQUEST

Upon receiving notification of Project commencement, the AP will request the following information regarding the pavement layers construction on periodic basis during the project as shown below. The request will be from SC/GEC for Legacy, Local Roads & Drainage and Expressways projects, and from PWA project manager for RIW Projects.

Information

 

Time Limit of delivering to ANAS

Action

3 months activities and production look ahead schedule

Last Thursday of every Month by 2:00 PM

 

Biweekly activities and production look ahead schedule

On Thursday of every Week by 2:00 PM

SC/GEC has to send through Email to AP, DC

Daily activity look ahead schedule

 

The day before the activities by 2:00 PM

Daily progress and activities completed

Every day by 2:00 PM

QC Records

 

Every three months

Updated

site

access

and

traffic

If necessary

 

management plan

 

In case information is not received as indicated in the table above, or is incomplete, “Unacceptable Observation” according to OP-21-F06 (Operating Procedure “Management of Non-Conformances”) will be issued to the relevant Party.

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

A.5.6

INFORMATION TRANSMISSION

The information listed in Sections 5.1 through 5.5 is transmitted by the relevant Parties via email to the ANAS AP and to the Document Controller using the following email: admin.docs@anas.com.qa

The information received is recorded in ANAS system. Document recording storage and retrieval will be according to ANAS Procedure “QP-01 Document Control”, and distributed throughout the ANAS Audit Team via email.

A.5.7

PROCEDURE EFFECTIVENESS CRITERIA

Timely collection and delivery of information;

Clarity of the Project Audit Proposal and effective implementation;

Timely recording of information in ANAS system.

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

A.5.8

FORMS/ RECORDS

Form / Record

Form/ Record Name

 

Satisfies

IS0

 

9001 Clause

Required by ISO 9001:2008

 

Other Forms/ Records

 

OP-01-F01

Project Initial Information Checklist

   

OP-01-F02*

Three Monthly Schedule

   

OP-01-F03*

Biweekly Schedule

   

OP-01-F04*

Daily Schedule

   

OP-01-F05*

Biweekly

Pavement

Materials

Production

 

Schedule

(*): The formats of these forms are optional for use by contractors or consultants, but information is required. Excel Spreadsheets of the same are available and can be requested from ANAS AP or DC.

APPENDIX A: OPERATING PROCEDURE OP01 REV5 COLLECTION OF PROJECT INFORMATION

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A SHGHAL - P UBLIC W ORKS A UTHORITY QA/QC P AVEMENT C ONSULTANCY S

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Table A.5-1 OP-01-F01

 

Project Initial Information Checklist

 

Project Code

 

NOTE ( Received, not received, or incomplete)

Project Name

 

1

Project contractual information:

   
 

1.1

GEC contract technical submission;

 
 

1.2

Contractor Project technical submission;

 
 

1.3

Quality Manual (Quality Assurance and Quality Control plans) for:

 
   

1.3.1

PMC/GEC/SC;

 
   

1.3.2

Contractor;

 
   

1.3.3

Subcontractor/Supplier;

 
   

1.3.4

Third Party Laboratory.

 

2

General Project information

   
 

2.1

Brief project description

   
   

2.1.1

Project location “GIS Map”;

 
   

2.1.2

General drawing layout with Chainages;

 
   

2.1.3

Road layers cross sections;

 
   

2.1.4

Interchanges / bridges, carriageway type, number of lanes;

 
   

2.1.5

Site accesses layout and traffic management plan if applicable.

 
 

2.2

Project Contact details

   
   

2.2.1

PMC (Project Manager)

 
   

2.2.2

SC (Senior RE, RE Roads, Senior Materials Engineer, Inspectors)

 
   

2.2.3

Contractor (Project Manager, QA/QC Manager, Plant Manager)

 
 

2.3

Project Detailed Design information;

 
   

2.3.1

Pavement design report

 
   

2.3.2

Materials and Mix design submittals as applicable:

 
     

2.3.2.1

Unbound Materials;

 
     

2.3.2.2

Cement Bound Materials;

 
     

2.3.2.3

Asphalt Courses.

 
 

2.4

Project Planning and Scheduling

 
     

Project baseline Schedule, to include (WBS, Project

 

2.4.1

calendars and work periods, activities definitions, duration and sequencing);

   

2.4.2

Three months look-ahead of pavement activities schedule (last Thursday of the Month on or before

 

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

 

Project Initial Information Checklist

Project Code

 

NOTE ( Received, not received, or incomplete)

Project Name

 
     

2:00pm);

 
   

2.4.3

Biweekly look-ahead of pavement activities schedule (every Thursday on or before 2:00pm);

 
   

2.4.4

Daily notification of pavement activities (one day before the planned activity on or before 2:00pm).

 
 

2.5

Project Quantities and Physical Progress

 
   

2.5.1

Quantities’ Calculations (For all Different Pavement Structures in the Project)

 
   

2.5.2

Areas calculations according to WBS;

 
   

2.5.3

Volumes calculations for each layer according to design drawing with related cross section;

 
   

2.5.4

Tonnage calculations for each layer according to design drawing with related cross section;

 
   

2.5.5

Biweekly Physical progress for each pavement layer (every Thursday on or before 2:00pm);

 
   

2.5.6

Daily progress and activities completed (daily on or before 2:00pm).

 
 

2.6

Material Sources and Suppliers:

 
   

2.6.1

Subgrade Suppliers and Crusher;

 
   

2.6.2

Aggregate bases Suppliers, Crusher and Wet Mix Plant;

 
   

2.6.3

CBM Suppliers, Crusher and Plant/s;

 
   

2.6.4

Asphalt Mixtures aggregates source, binder source, PMB Suppliers, Plant/s.

 
 

2.7

Pavement material production construction and quality control documents

 
   

2.7.1

Stockpiles management plans

 
   

2.7.2

Approved Method Statement for pavement layers production and construction;

 
   

2.7.3

Approved ITP’s for pavement layers;

 

3

Materials’ Testing Laboratory and Contacts:

 
 

3.1

Contact details of the third party laboratory (legal name, Laboratory Manager Name).

 

4

Materials Specification Requirements (QCS 2010, PWA Guides, etc.).

 
 

Materials testing results (Summary Logs) for all pavement layers

 

5

from Third-Party Laboratories to be sent on Biweekly basis (every other Thursday on or before 2:00pm).

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Project Initial Information Checklist

Project Code

NOTE ( Received, not received, or incomplete)

Project Name

 

Any Change and/or new instructions regarding the specification

6

requirements officially given to the contractor shall also be provided to ANAS within Two working days.

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Table A.5-2 OP-01-F02 Three Monthly Schedule

– 11/S013/G Table A.5-2 OP-01-F02 Three Monthly Schedule A PPENDIX A: O PERATING P ROCEDURE OP01

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Table A.5-3 OP-01-F03 – Biweekly Schedule

– 11/S013/G Table A.5-3 OP-01-F03 – Biweekly Schedule A PPENDIX A: O PERATING P ROCEDURE OP01

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Table A.5-4 OP-01-F04 – Daily Schedule

– 11/S013/G Table A.5-4 OP-01-F04 – Daily Schedule A PPENDIX A: O PERATING P ROCEDURE OP01

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ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Table A.5-5 OP-01-F05 – Biweekly Pavement Materials Production Schedule

– Biweekly Pavement Materials Production Schedu le A PPENDIX A: O PERATING P ROCEDURE OP01 R

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AQB-T03-QMSDS-PRO-MOA-231014-0-5

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G
ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Page intentionally left blank

APPENDIX A: OPERATING PROCEDURE OP01 REV5 COLLECTION OF PROJECT INFORMATION

PAGE A-18

AQB-T03-QMSDS-PRO-MOA-231014-0-5

Revision Number: Prepared By: 3 Mohammed Anshasi Romolo Neri Issue Date: Reviewed By: 31/08/2014
Revision Number: Prepared By: 3 Mohammed Anshasi Romolo Neri Issue Date: Reviewed By: 31/08/2014
Revision Number: Prepared By: 3 Mohammed Anshasi Romolo Neri Issue Date: Reviewed By: 31/08/2014

Revision Number:

Prepared By:

3

Mohammed Anshasi Romolo Neri

Issue Date:

Reviewed By:

31/08/2014

James Maina

Davide Lioi

Effective Date:

Approved By:

04/11/2014

Hussain Bahia

Revision History:

Revision

Revision

Description of changes

Number

Date

0 26-06-2014

Initial Release

1 11/08/2014

2 31/08/2014

3 04/11/2014

ID Coding Updating

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Requested by

Leading Pavement Expert

Leading Pavement Expert

Leading Pavement Expert

Leading Pavement Expert

PAGE B-1

AQB-T03-QMSDS-PRO-JAM-110414-0-3

Expert P AGE B-1 AQB-T03-QMSDS-PRO-JAM-110414-0-3 APPENDIX B: I NTEGRATED A UDITING P ROCEDURE Position:

APPENDIX B: INTEGRATED AUDITING PROCEDURE

Position:

Quality Auditor Quality Auditor

Position:

Pavement Expert Pavement Expert Assistant

Position:

Leading Pavement Expert

Identification of required skills for each audit activities Replacing QMS Audits with PQMA Audits and
Identification of required skills for each audit
activities
Replacing QMS Audits with PQMA Audits and
make them part of other Audits
ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G
ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

 

TABLE OF CONTENTS

APPENDIX B:

INTEGRATED AUDITING PROCEDURE

B-1

 

B.1

PURPOSE BACKGROUND AUDIT SCOPE AND OBJECTIVES REVIEW OF PAVEMENT DESIGN AUDIT TEAM: REQUIRED SKILLS, ROLES AND ACTIVITIES AUDIT ITEMS/ACTIVITIES LINKS REPORTING AND OUTCOME APPLICABLE AUDITING PROCEDURE AUDIT OF MATERIAL SUPPLIERS AND PRODUCTION FACILITIES AND LABORATORY AT-PLANT AUDIT TEAM: REQUIRED SKILLS, ROLES AND ACTIVITIES AUDIT ITEMS/ACTIVITIES LINKS REPORTING AND OUTCOME APPLICABLE AUDITING PROCEDURE

B-3

B.2

B-4

B.3

B-4

B.4

B-5

B.4.1

B-5

B.4.2

B-5

B.4.3

B-5

B.4.4

B-6

B.4.5

B-6

B.5

B-7

B.5.1

B-7

B.5.2

B-8

B.5.3

B-10

B.5.4

B-10

B.5.5

B-10

B.6

CONSTRUCTION PRACTICE AUDITS

B-11

B.6.1

AUDIT TEAM: REQUIRED SKILLS, ROLES AND ACTIVITIES AUDIT ITEMS/ACTIVITIES, EXTENT AND FREQUENCIES LINKS REPORTING AND OUTCOME APPLICABLE AUDITING PROCEDURE

 

B-11

B.6.2

B-12

B.6.3

B-14

B.6.4

B-14

B.6.5

B-15

B.7 AUDIT OF THIRD PARTY LABORATORY

B-16

B.7.1

AUDIT TEAM: REQUIRED SKILLS, ROLES AND ACTIVITIES AUDIT ITEMS/ACTIVITIES LINKS REPORTING AND OUTCOME APPLICABLE AUDITING PROCEDURE AUDIT OF CONSTRUCTED PAVEMENT (POST-CONSTRUCTION)

B-16

B.7.2

B-16

B.7.3

B-17

B.7.4

B-17

B.7.5

B-17

B.8

B-18

B.8.1

AUDIT TEAM: REQUIRED SKILLS, ROLES AND ACTIVITIES AUDIT ITEMS/ACTIVITIES LINKS REPORTING AND OUTCOME APPLICABLE AUDITING PROCEDURE

 

B-18

B.8.2

B-18

B.8.3

B-18

B.8.4

B-18

B.8.5

B-19

B.9 INTEGRATED AUDIT PROGRAM/SCHEDULE

B-20

B.9.1

RESOURCE PLAN FOR INTEGRATED AUDITING

B-21

B.10

B-23

B.11

INTEGRATED AUDIT REPORTS AND PERIODIC UPDATES MATERIALS SAMPLING AND TESTING FREQUENCIES

B-24

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

 

PAGE B-2

AQB-T03-QMSDS-PRO-JAM-110414-0-3

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G B.1

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

B.1

PURPOSE

The purpose of this document is to define the objectives of the Integrated Audits to cover all Key Supply Chain Partners (KSCPs) involved in the delivery of a road construction project for PWA. The integrated audit described in this procedure represents the audit execution phase of the overall auditing plan shown in Figure 1. The document also defines the audit activities, extents and frequencies, audit teams, schedule for each type of audits. \

audit teams, schedule for each type of audits. \ Figure 1. Project Audit and Testing Procedures

Figure 1. Project Audit and Testing Procedures

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

PAGE B-3

AQB-T03-QMSDS-PRO-JAM-110414-0-3

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G
ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

B.2

BACKGROUND

 

Based on the critical review of the auditing conducted during the first year of the QA/QC project, during which individual disconnected audits of various production and construction activities were conducted, ANAS agreed with PWA that conducting integrated project audits is a better approach to monitor quality. Integrated audits include linking all required audit activities related to a project and covering larger project audit area. The audits require spending more time analyzing projects, preparing and conducting the audits, and integrating the results from auditing activities of all KSCPs.

B.3

AUDIT SCOPE AND OBJECTIVES

 

The Integrated Audit spans across the supply chain related to road construction for PWA Projects. The Supply Chain can be grouped into four major categories:

Pavement design

 

Materials Supplier and Production Facilities

 
 

o

Material Supplier 1 (Aggregate and Asphalt Binder),

o

Mixtures/Materials Production

 
 

Crusher plants;

Wet mix plants;

Asphalt plants.

Site Laboratories

Construction Practices and Project Quality Management

 

o

Program Management Consultants;

 

o

Supervision Consultants;

o

Construction Contractors and Sub-Contractors;

o

Third Party Laboratories.

 

Post construction

 
 

o

International Roughness Index (IRI) as per project requirements.

The Integrated Audit activities include the following Steps:

 

1. Review the Pavement Design Report and project construction layout;

2. Auditing the materials handling, storage and transportation (*);

3. Production Facilities and Laboratory at-Plant;

 

4. Construction Practices;

 

5. Third Party Laboratory (material sampling, testing and QC records) - For planning the PQMA audits and collecting QC data;

6. Quality Management protocols for all KSCPs - For auditing of project quality management procedures as related to technical matters.

1 Audits on bitumen sources/Suppliers (i.e. refineries, WOQOD) will be confirmed upon finalization of materials importation framework Audits on aggregates sources/crushers outside state of Qatar (UAE) to be confirmed upon finalization of materials importation framework

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

PAGE B-4

AQB-T03-QMSDS-PRO-JAM-110414-0-3

B.4 R EVIEW OF P AVEMENT D ESIGN B.4.1 Required Skills Job Title (Knowledge of)
B.4 R EVIEW OF P AVEMENT D ESIGN B.4.1 Required Skills Job Title (Knowledge of)
B.4 R EVIEW OF P AVEMENT D ESIGN B.4.1 Required Skills Job Title (Knowledge of)

B.4

REVIEW OF PAVEMENT DESIGN

B.4.1

Required Skills

Job Title

(Knowledge of)

Pavement Design methods

Leading

QHDM

Pavement

AASHTO 1993

Expert

M-E Pavement design

Pavement materials properties and behaviours

Pavement Design methods

Pavement

QHDM

Expert

AASHTO 1993

M-E Pavement design

Pavement materials properties and behaviours

B.4.2

Number of staff required per Audit team

1

1

Audit Extent

AUDIT ITEMS/ACTIVITIES

Audit Item/Activity

PV Pavement Design Check

PV.1 General Check- Pavement Design Report (PDR) Content

PV.2

Geotechnical Investigation

Concept

PV.3 Design Traffic

Preliminary

PV.4 Pavement Design Inputs - AASHTO

Detailed

1993 Method PV.5 Pavement Design Inputs - M-E Design Method

PV.6

Pavement Design Inputs - QHDM

B.4.3

LINKS

Audit activities

Audit frequencies

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Activities

(See B.4.2)

PV.1 to PV.6

PV.1 to PV.6

Variable frequency

In case of Rejection

PAGE B-5

AQB-T03-QMSDS-PRO-JAM-110414-0-3

of Rejection P AGE B-5 AQB-T03-QMSDS-PRO-JAM-110414-0-3 This audit is the first to be performed on a

This audit is the first to be performed on a project. The objective is to review the complete process that was followed in the pavement design to ensure its conformance to the required design method.

AUDIT TEAM: REQUIRED SKILLS, ROLES AND ACTIVITIES

General Roles and Responsibilities Participate and approve the review done by Pavement Expert. Review and
General Roles and
Responsibilities
Participate and
approve the review
done by Pavement
Expert.
Review and sign the
Certificate.
Perform review of
pavement design
reports. Fill out the
Design Review Sheet
(DRS) and draft
Certificate of
approval.
Three days for each project. The review of pavement design reports for the following design
Three days for each project. The review of pavement design reports for the following design
Three days for each project. The review of pavement design reports for the following design

Three days for each project. The review of pavement design reports for the following design stages:

Three days for each project. The review of pavement design reports for the following design stages:
Three days for each project. The review of pavement design reports for the following design stages:

Review of pavement design reports will identify pavement layers and materials quantities. This information is used to determine:

Pavement material types, layer thicknesses and quantities

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G
ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

B.4.4

REPORTING AND OUTCOME

Report of the review of pavement design report will include:

Completed Design Review Sheet (DRS)

 

Pavement design certificate

Pavement material types, layer thicknesses, and quantities

B.4.5

APPLICABLE AUDITING PROCEDURE

Operating procedure for the Review of Pavement Design Report (OP-14) – Appendix C3 in the Audit Manual.

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

PAGE B-6

AQB-T03-QMSDS-PRO-JAM-110414-0-3

B.5 B.5.1 Required Skills Job Title Number of   staff (Knowledge of)   required per
B.5 B.5.1 Required Skills Job Title Number of   staff (Knowledge of)   required per
B.5 B.5.1 Required Skills Job Title Number of   staff (Knowledge of)   required per

B.5

B.5.1

Required Skills

Job Title

Number of

 

staff

(Knowledge of)

 

required per

 

Audit team

Mixture design

Materials

1

 

specifications and

Engineer

requirements

(This resource will

Plant operations

visit the Plant only when necessary)

Materials storage

 

and transportation

Training for

 
 

personnel

Production plant,

Plant Specialist

1

equipment and

(Quality Auditor

operating

Junior)

procedure

Control system

and software

Testing

Laboratory

1

procedure,

Supervisor

equipment and

maintenance

Materials

handling, storage

and transportation

ISO 17025

requirements

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Activities (See B.6.2) PF.A.11 – PF.A.18 PF.C.7-PF.C.12 PF.D.2 PF.A.1 PF.B.1 - PF.B.3 PF.C.1 PF.A.18 PF.D.1
Activities
(See B.6.2)
PF.A.11 –
PF.A.18
PF.C.7-PF.C.12
PF.D.2
PF.A.1
PF.B.1 - PF.B.3
PF.C.1
PF.A.18
PF.D.1
PF.D.3
in
PAGE B-7
AQB-T03-QMSDS-PRO-JAM-110414-0-3
PF.D.3 in PAGE B-7 AQB-T03-QMSDS-PRO-JAM-110414-0-3 A UDIT OF M ATERIAL S UPPLIERS AND P RODUCTION

AUDIT OF MATERIAL SUPPLIERS AND PRODUCTION FACILITIES AND LABORATORY AT-PLANT

The scope of this audit covers verification of the systems and processes in material handling and storage, mixtures and their productions - at-plant. In addition, materials testing facilities are also included in this audit.

AUDIT TEAM: REQUIRED SKILLS, ROLES AND ACTIVITIES

General Roles and Responsibilities Confirm audit schedule Implementation and compliance with applicable standards and
General Roles and
Responsibilities
Confirm audit schedule
Implementation and compliance
with applicable standards and
ANAS procedures.
Perform audit on process and
materials.
Technical review of QC
document and records
Communicate with Key Supply
chain partners.
Prepare unacceptable
observations, ANCR
Make recommendation for
ongoing improvement.
Verify the adequacy and
condition of plant equipment and
process
Report any fault/malfunction to
the quality auditor
Prepare the audit form
Conduct Audits on plant and site
laboratories
Verify laboratory equipment
availability and compliance with
the standards
Verify QC sampling and testing
procedures and frequency
the plant and laboratory
Complete laboratory audit form
for the equipment and the
witnessed testing procedure
Report any laboratory non-
conformance and deviation to
ANAS senior laboratory
manager
Required Skills Job Title Number of   staff (Knowledge of)   required per   Audit
Required Skills Job Title Number of   staff (Knowledge of)   required per   Audit
Required Skills Job Title Number of   staff (Knowledge of)   required per   Audit

Required Skills

Job Title

Number of

 

staff

(Knowledge of)

 

required per

 

Audit team

Materials

sampling

procedures and

requirements

Technician

(Sampling

Supervisor)

1

Materials

 
 

handling, storage

and transportation

ISO 17025

 
 

requirements

Materials

 
 

sampling

procedures

Sampling

Technicians

2

 

equipment

maintained

condition

ISO 19011

 
 

requirements

Quality

Assistant

Expert

1

Project Quality

Plan (PQP)

Training for staff

B.5.2

AUDIT ITEMS/ACTIVITIES

Audit Item/Activity

PF.A Verify asphalt plant

PF.A.1 Equipment and process

PF.A.2

Cold feeding system (bins and

PF.A.3

conveyors) Dryer and hot elevator

PF.A.4

Mineral filler feeding and weighing

PF.A.5

Plant screens

PF.A.6

Hot bins

Audit Extent*

Up to 300t of materials

See B.13 for testing details

PF.A.7 Bitumen storage tanks (heating and agitation) and feeding lines

PF.A.8

Plant scales

PF.A.9

Plant mixer/pug mill

PF.A.10 Plant control system (mix proportioning against JMF)

PF.A.11

PF.A.12 Visual verification of materials,

Verify materials and process

storage and handling

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Activities (See B.6.2) PF.A.18 PF.B.4 PF.C.12 PF.A.18 PF.B.4 PF.C.12 are properly and in good PF.D
Activities
(See B.6.2)
PF.A.18
PF.B.4
PF.C.12
PF.A.18
PF.B.4
PF.C.12
are
properly
and
in
good
PF.D
Variable Frequency*
 Once every 15,000t for base course
OR
 10,000t
when
2 consecutive
ANCRs or 3 different ANCRs are
generated.
PAGE B-8
AQB-T03-QMSDS-PRO-JAM-110414-0-3
are generated. PAGE B-8 AQB-T03-QMSDS-PRO-JAM-110414-0-3 General Roles and Responsibilities Manage and supervise
General Roles and Responsibilities Manage and supervise sampling teams Assure compliance with procedures and
General Roles and
Responsibilities
Manage and supervise sampling
teams
Assure compliance with
procedures and frequency
according to specifications.
Communicate with SC materials
engineer and QC third party
laboratory
Assure samples are marked,
identified and properly sealed
Conduct sampling according to
standards
Make sure sampling tools and
Insure proper handling and
transporting of the sample
Perform PQMA audits on
production facilities
Verify quality document,
procedures and records related
to material stockpiling
Verify quality document,
procedures and records related
to material sampling and testing
Verify personnel training and
certification
document, procedures and records related to material sampling and testing Verify personnel training and certification
document, procedures and records related to material sampling and testing Verify personnel training and certification
document, procedures and records related to material sampling and testing Verify personnel training and certification
document, procedures and records related to material sampling and testing Verify personnel training and certification
document, procedures and records related to material sampling and testing Verify personnel training and certification
document, procedures and records related to material sampling and testing Verify personnel training and certification
Audit Item/Activity PF.A.13 PF.A.14 Verifying materials delivery and traceability from the Supplier/source PF.A.15
Audit Item/Activity PF.A.13 PF.A.14 Verifying materials delivery and traceability from the Supplier/source PF.A.15
Audit Item/Activity PF.A.13 PF.A.14 Verifying materials delivery and traceability from the Supplier/source PF.A.15

Audit Item/Activity

PF.A.13

PF.A.14 Verifying materials delivery and traceability from the Supplier/source

PF.A.15 Verify materials (aggregates, binder and asphalt mix), QC test records, quality control charts and testing frequency.

PF.A.16

PF.A.17 Communicate/co-ordinate with

plant Manager and Supervision Consultant Sampling and testing (aggregates stockpiles, binder, hot bins and asphalt mix)

PF.A.18

Transportation equipment

Verify plant ES&H provisions

PF.B

Verify

Subbase/

Subgrade

crusher

 

equipment and process

 

PF.B.1

PF.B.2

PF.B.3

PF.B.4

Receiving hoppers condition Grizzly/Screen condition Clay extractor condition Sampling and testing

PF.C

Verify Sub-base / CBM central mixing

plant

PF.C.1

Plant scales

PF.C.2

Weighing hoppers

PF.C.3

Control cabin

PF.C.4

Plant mixer

PF.C.5

Ticketing system

PF.C.6

Plant control system

PF.C.7

Visual verification of materials,

PF.C.8

storage and handling Verifying materials delivery and

PF.C.9

traceability from the Supplier/source Verify materials, QC test records

PF.C.10

ES&H provisions

PF.C.11

Communicate/coordinate with

PF.C.12

plant Manager and Supervision Consultant Sampling and testing (aggregate stockpiles and mix)

PF.D PQMA of plant/site laboratory.

Audit Extent*

Up to 500 m 3 of materials

See B.13 for testing details

Up to 500 m 3 of materials

See B.13 for testing details

One day

PF.D.1 Verify sampling and testing process (aggregates, binder and

mix)

PF.D.2 Verify QC records PF.D.3 Verify laboratory equipment (availability and calibration) PF.D.4 Verify laboratory technicians competency and certification

PF.E

Visual

inspection

of

aggregates

 

stockpile

PF.E.1

Proper separation between different sizes Stockpile marking and signage No segregation or contamination Stockpile building and shape Delivery tickets

PF.E.2

PF.E.3

PF.E.4

PF.E.5

One day

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Variable Frequency*

Once every 20,000 m 3 , or

OR

15,000 m 3 when 2 consecutive ANCRs or 3 different ANCRs are generated.

Once every 15,000 m 3 ,

OR

10,000 m 3 when 2 consecutive ANCRs or 3 different ANCRs are generated.

Once at the beginning of the project

Once every three months to be performed at the same time as other audit activities, OR

within one month after the previous audit in case of Unacceptable Observation.

Once at the beginning of the project

Once every six months to be performed at the same time as other audit activities, OR

within one month after the previous audit in case of Unacceptable Observation.

PAGE B-9

AQB-T03-QMSDS-PRO-JAM-110414-0-3

one month after the previous audit in case of Unacceptable Observation . P AGE B-9 AQB-T03-QMSDS-PRO-JAM-110414-0-3
one month after the previous audit in case of Unacceptable Observation . P AGE B-9 AQB-T03-QMSDS-PRO-JAM-110414-0-3
  ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G
  ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G
 

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

Notes *: The figures used in this Table are indicative only, productivity will be monitored and the variable frequency will be adjusted accordingly

B.5.3

LINKS

As part of the Audit, the plant will be required to provide a list of suppliers of their raw materials

The plant will also be required to provide a list of projects and/or KSCPs that they have or intend to supply.

This list will be cross-checked with the reports of Pavement design and Construction Practices for consistency.

The QC testing results, if available, will be analysed in conjunction with the materials testing from Task 5.

B.5.4

REPORTING AND OUTCOME

 

Report of the audit of production facilities will include:

 

Completed

Audit

Forms

and

narrative

of

critical

and

unacceptable

 

observations

Summary of QC results

 

IDs of samples and locations of sampling

 

ANCRs, MUOs and UOs

 

B.5.5

APPLICABLE AUDITING PROCEDURE

 

Task 7 Plant Prequalification Procedure (OPT07-01)

 

Audit on Production Facilities (T3PF-02) – Appendix C8 of the Audit Manual

Sampling procedure (AnnexOP-21-A3) - Appendix C6 of the Audit Manual

Technical audit for third party laboratories (OP-22) – Appendix C10 of the Audit Manual.

APPENDIX B – INTEGRATED AUDITING PROCEDURE REV 3 INTEGRATED AUDITING PROCEDURE

 

PAGE B-10

 

AQB-T03-QMSDS-PRO-JAM-110414-0-3

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G
ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

ASHGHAL - PUBLIC WORKS AUTHORITY QA/QC PAVEMENT CONSULTANCY SERVICES PROJECT ID: IA/10 – 11/S013/G

B.6

CONSTRUCTION PRACTICE AUDITS

As for any process, pavement construction has inputs and outputs. Identifying, monitoring, controlling, and improving the process inputs will directly affect the quality of the process outputs. The scope of this audit covers the verification of all the major process inputs directly related to pavement construction practices, which are expected to impact on the quality of the constructed pavement.

B.6.1

AUDIT TEAM: REQUIRED SKILLS, ROLES AND ACTIVITIES

Required Skills

Job Title

Number of staff required per Audit team

General Roles and Responsibilities

Activities

(Knowledge of)

(See B.7.2)

Construction process

and management

Quality Auditor

1 Confirm audit

 

CP.A.1

to

schedule

CP.A.10

Construction

equipment

Implementation and

CP.B.1

to

compliance with

CP.B.9

Materials behaviour

applicable standards

during construction

Influence of

and ANAS

procedures.

CP.C.1

CP.C.6