02 - Civil Procurement

ITB FOR PROJECT NAME PART II PROJECT SPECIFICATIONS

SECTION 4 ‐ PROJECT EXECUTION INSTRUCTIONS 4.7 QUALITY ASSURANCE & QUALITY CONTROL

4.7.2 INSPECTION & TESTING

Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

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INSPECTION AND TEST PLAN (ITP) FOR READY MIX CONCRETE

BATCH PLANT MANAGEMENT

Print Name Signature Name of Company Doc No: EPM-ITP-CP-001

Prepared By: (1)

Approved By: (2) Revision: 0

Company App: Stage: Procurement Discipline: CIVIL PROJECT: Date:

Location: (3) Item Name (3): Tag No (3): Page:

Sr. No Inspection Activity Characteristic Verified (4) Reference

Document (5)Acceptance Criteria (6)

Verifying

Document (7)

Inspection Responsibility

Remarks Vendor Contr SABIC

1.0 Batch Plant

1.1 Facility Area for storage of material, mixing plant, infra structures, work shop etc

SES B51-S01Project specification PEI

Approved vendor list I S S

1.2 Plant equipments & vehicles

Equipment and vehicles list Sufficiency, capacity SES B51-S01 Project

specification PEI Equipment list I S S

1.3 Laboratory set up Facility provided to laboratory SES B51-S01

Project specification PEI

Records/third party approval letter I S S

2.0 Quality management system




Sub Sec. 4.7.2

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Sr. No

Inspection Activity Characteristic Verified (4) Reference Document (5)

Acceptance Criteria (6)

Verifying Document (7)

Inspection ResponsibilityRemarks

Vendor

Contr

SABIC

2.1 Human Resources

Sufficient Quality Staff, competitiveness, training record etc

SES B51-S01ISO 9001-2008

Project specification PEI records I S/A S/R

2.2 Documents

Quality manual, organization chart, quality policy and objective, Management review report, Quality control procedure, quality manager and staff, technician details etc

SES B51-S01ISO 9001-2008

Project specification PEI Organization charts,

procedures and records I S/A S/R

2.3 Records

All test reports /Batch tickets. Standard deviation Graph

SES B51-S01ISO 9001-2008


Test reports A R R

2.4 Certification Certified By ISO 9001-2008 as applicable SES B51-S01


Certificate R R R

3.0 Production and Quality Control




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Vendor

Contr

SABIC

3.1 Documents

Production procedure, Calibration of testing and measuring equipments ( certificate, validity etc)

SES B51-S01


Documents and records/spot inspection results

I S/R S/R

3.2 Material

cement source

Cement ; type and suppliers approval, For cement manufactured in the Kingdom of Saudi Arabia, manufacturer’s test certification confirming cement compliance with the requirements of SES B51-S01

Aggregate( Fine and Coarse ): suppliers approval with detail of query location, aggregate type, gradation curve, &sieve analysis, shape, surface texture, and moisture content. Test reports for clay, for chloride and sulphate ion, reactive silica, soundness Los Angles abrasion, moisture content

SES B51-S01


SES C04-S02 and related ASTM and AASHTO standards

Supplier approval letter, vendor code, MDS, test reports

A A A




Sub Sec. 4.7.2

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Rev. Date Mar 2010

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Vendor

Contr

SABIC

Aggregates: Source and supplier with test certificates

Aggregate( Fine and Coarse ): suppliers approval with detail of query location, aggregate type, gradation curve, &sieve analysis, shape, surface texture, and moisture content. Test reports for clay, for chloride and sulphate ion, reactive silica, soundness Los Angles abrasion, moisture content

SES B51-S01and related ASTM and ACI standards


Supplier approval letter, vendor code, third party approval MDS, Third party test reports

A A A

Water: Source and supplier with test certificates

Water; source approval with test reports like PH Value, chloride and sulphate ions test reports



Supplier approval letter, vendor code, third party approval

Third party test reports

A A A

Chemical Admixture: Supplier and test certificates

Chemical admixtures : supplier approval,



Supplier approval letter, vendor code, MDS, test reports

A A A




Sub Sec. 4.7.2

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Rev. Date Mar 2010

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Vendor

Contr

SABIC

Mineral Admixture: Source and supplier with test certificates

Silica Fume: supplier approval certification with the test reports for silica fume like silicon content, chemical analysis loss on ignition etc



Suppliers compliances certificate with all test reports

A A A

3.3

Design Mix for Concrete of particular strength

(Trail Mix Preparation and test)

36 cylinders for each mix. Fresh concrete test –temperature, slump, unit weight, air content.

Compressive strength for 7 and 28 days

Calculating standard deviation

SES B51-S01

Project specification

Third party test reports, standard deviation calculation sheet

I H H

4.0 Periodic testing/spot inspection of material

4.1 Cement Type & storage SES B51-S01 Project specification

Visual inspection report I S S

4.2 Curing water Biweekly SES B51-S01

SES B51-S01

and project

QVD

Third party report I W2 W2




Sub Sec. 4.7.2

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Sr. No





Vendor

Contr

SABIC

4.3 Aggregate ( coarse and fine )

Test for clay :For every 100 Cum concrete produced SES B51-S01

SES B51-S01

and project specifications

SES B51-S01

QVD


4.3

Test for chloride and sulphate: For every 100 Cum concrete produced

SES B51-S01

Project specifications SES B51-S01

QVD


Reactive silica, soundness, Los Angeles abrasion and moisture test For every three months

SES B51-S01

Project specifications

SES B51-S01 QVD


Visual storage check: random SES B51-S01


SES B51 S01

Inspection report I S S

4.4 Silica Fume % of silicon and chemical analysis : As requested by SABIC

SES B51-S01Project specifications

SES B51-S01

Inspection report I H H




Sub Sec. 4.7.2

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Rev. Date Mar 2010

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Vendor

Contr

SABIC

4.5 Usage of admixture, Concentration of Calcium nitrate if required

Spot checking/ and sampling SES B51-S01


SES B51-S01 Inspection report/Test report I S S

5.0 Hot weather concrete

5.1 Precautions

Ice; source and usage

Shading

Controlling temperature etc

SES B51-S01



5.2 In house laboratory test ( Conducted by batching Plant )

Test and reports SES B51-S01



Abbreviations: SES = SABIC Engineering Standards, PEI=Project Execution Instructions, QVD=Quality Verifying Document

Legend: (1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative.




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

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(2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure, etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. All forms and checklists shall be

attached to the ITP and submitted to the Company during Approval Stage. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and Company for each inspection step. Inspection responsibility shall

be ‘I’ for Inspection, ‘R’ for review, ‘A’ for approval, ‘S’ for Surveillance, “W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 5 of 140

INSPECTION AND TEST PLAN (ITP) FOR ASPHALT

BATCH PLANT MANAGEMENT

Print Name

Signature Name of Company Doc No: EPM-ITP-

CP-002Prepared By: (1)

Approved By: (2) Revision 0

Company App: Stage Procurement Discipline: Civil PROJECT: Date:

Location: (3) Item Name (3): Tag No (3): Page:

Sr.

No


Acceptance

Criteria (6)

Verifying

Document (7)

Inspection Responsibility

Remarks Sub Contr

Contr Comp.

1.0 Plant

1.1 Facility

Type of plant – stationary, or portable. Type of mix – Batching or drum mix Area for storage of material, mixing plant, infra structures, work shop etc

SESC04-S02 Project specification and PEI

Approved vendor list I S S

1.2 Plant equipments & vehicles Equipment and vehicles list Sufficiency, capacity SES C04-S02

Project specification and PEI

Equipment list I S S

1.3 Laboratory set up Facility provided to laboratory SESC04-S02 Project specification and PEI

Records/third party approval letter

I S S

2.0 Quality management system

2.1 Human Resources Sufficient Quality Staff, competitiveness, training record etc

ISO 9001-2008

Project specification and PEI

records i S/A S/R




Sub Sec. 4.7.2

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Rev. Date Mar 2010

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Sr. No





Vendor

Contr

SABIC

2.2 Documents

Quality manual, organization chart, quality policy and objective, Management review report, Quality control procedure,, quality manager and staff, technician details etc

SES C04-S02

ISO 9001-2008


Organization charts, procedures and records I S/A S/R

2.3 Records All test reports including aggregate, bitumen, etc

SES C04-S02ISO 9001-2008

Project specification PEI Test reports A R R

2.4 Certification Certified by local / International body

SES C04-S02 Project specification PEI

Certificate R R R

3.1 Documents

Production procedure, Calibration of testing and measuring equipments ( certificate, validity etc)

SES C04-S02


Documents and records/spot inspection results

I S/R S/R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

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Sr. No





Vendor

Contr

SABIC

3.2

Material approval

Asphalt cement and Aggregates

Asphalt cement: Supplier approval, penetration grade, Flashpoint, viscosity, ductility, solubility in trychloro ethylene, Shall not foam when heated, water, moisture free Aggregate: Amount of Material Finer than No. 200 Sieve ,Unit Weight of Aggregate , Sieve analysis of fine ,Coarse aggregates and mineral filler, Abrasion of coarse aggregate, Los Angeles Machine, Soundness of Aggregates , Plastic Fines in graded

t d S il b U

SES C04-S02and related ASTM and AASHTO standards

SES C04-S02 and related ASTM and AASHTO standards

MDS, Test reports for Asphalt cement and aggregate

A A A




Sub Sec. 4.7.2

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Rev. Date Mar 2010

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Vendor

Contr

SABIC

Design Mix for asphalt base course


Gradation of mix, asphalt content, and the test specified in co4-S04 table 2, and 5. If the mixture is produced in a mixing plant having automatic controls and a printout system and the controls are in proper calibration, asphalt content compliance shall be determined from recorded data. Hot-bin analysis together with batch-weight readout data shall be used to determine composition compliance.

SES C04-S02


Inspection report, mix design , trail mix test reports

I H H




Sub Sec. 4.7.2

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Rev. Date Mar 2010

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Vendor

Contr

SABIC

Design Mix for asphalt Surface course


Gradation of mix, asphalt content, and the test specified in co4-S04 table 3, and 5. If the mixture is produced in a mixing plant having automatic controls and a printout system and the controls are in proper calibration, asphalt content compliance shall be determined from recorded data. Hot-bin analysis together with batch-weight readout data shall be used to determine composition compliance

SES C04-S02


Inspection report, mix design , trail mix test reports

I H H

3.3 Periodic testing/spot inspection of aggregates, bitumen etc

Log and list of equipment, calibration certificates, validity dates etc.

SES C04-S02


PEI Calibration log and certificates I W1/Spot

witness W1/Spot witness




Sub Sec. 4.7.2

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Rev. Date Mar 2010

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Vendor

Contr

SABIC

3.4 Periodic testing /spot inspection of Mix

SES C04-S02Project specification PEI

I W1/Spot witness

W1/Spot witness

Legend: Abbreviations: SES = SABIC Engineering Standards, PEI=Project Execution Instructions, QVD=Quality Verifying Document

Legend: (1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure, etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. All forms and checklists shall be

attached to the ITP and submitted to the Company during Approval Stage. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and Company for each inspection step. Inspection responsibility shall

be ‘I’ for Inspection, ‘R’ for review, ‘A’ for approval, ‘S’ for Surveillance, “W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 5 of 140

02 - Civil Procurement

Documents

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