A 7 we Gy ’ ¥ ve LP ve Sree «<< “aay @ 9 Qual ity control & qual ity assurance j % 9 ah QU Figoonen In Construction % ) . 9 7 o@~ BECM 4201 ’ » ww SaaS “ae.we Quality Control & Quality Assurance cote + Itis very important to have a good quality control process on a project. Qc - QC is ultimately just making sure that they are completing the work safely and in compliance with the contract. QA - QA is spot checking contract compliance, test results, and ultimately just making sure that the Quality Control Processes is working.a’ » 9 Quality Control a + Feigenbaum (1991): 4 steps in quality control 1. Setting Standards: Determining the required cost—quality, performance— quality, safety—quality, and reliability—-quality standards for the products. 2.__ Appraising Conformance: Comparing the conformance of the manufactured product, or the offered service to the standards. > 2. 0) ’ yy, \a © . ¥ y 2 oo 3._Acting When Necessary: Correcting problems Br their causes throughout the full range of those marketing, design, engineering, production, and maintenance factors that influence user satisfaction. 4. Planning of Improvements: Developing a continuing effort to improve the cost, performance, safety, and reliability standards.Steps for Quality Control Control involves a universal sequence of steps as follows: + 1. Choose the control subject, that is, choose what we intend to regulate. + 2. Establish measurement. * 3 Establish standard of performance, product goal, and process goals. + 4, Measure actual performance. + 5. Compare actual measured performance against standards. * 6. Take action on the difference.Quality Control + Gryna (2001):The control process involves oe a! actual performances, comparing it with some standards, and then taking action if observed performance _is significantly different_from the standard. The control process is in the nature of a feedback loop as shown in Figure. Quality Control Process Sensor Goal Actuator fk ——-@—— comparisona © ’ > 2 QC process in Construction " Ls ae * The quality of construction is to be maintained as per» role ' specifications. It is important that quality requirements be _a satisfied and production schedules are met. Therefore, quality control in construction can be achieved through the integration of the following aspects: . Quality of constructed facility . Quality of Design . Conforming to Quality . Quality of Performance . Characteristics of Quality moowp(A) Quality: Quality of a constructed facility may be verified based on some " instincts or factors. These may be considered as follows : > + Aesthetics + + Strength + + Durability + + Safety + +Economy + + Maintainability + © Reliability + + Degree of satisfaction of the end user + + Versatility of use for many purposesB) Quality of Design: Quality of design of a construction is concerned with the specifications which have to be conformed with. A good quality of design must ensure consistent performance of the facility for the entire life span of the facility. The design of the facility should be done in such a way that all possible modes of failures are considered and appropriate inputs are ingrained in the design to take care of them.C) Conforming to Quality: Conforming to quality means the quality product/construction to be of a required order. Use of proper quality of materials, proper work sequences, proper types of equipment and inspections from time to time are factors which should be considered. Itis to noted that a higher quality of design increases the cost but a higher quality of conformity with the design saves the investment.D) Quality of Performance: It is connected with how well the constructed facility gives its performance. It depends on both the quality of design and the quality of conformance. It may be easily understood that even a best design may not be able to provide us with something which is going to be the best in terms of performance if the quality of conformance is poor. The reverse is also true. A proper quality of conformance also can not provide a good quality of constructed facility if the quality of design of the facility is not good.+ (E) Characteristics of Quality: Quality characteristics may be defined in terms of parameters which may be of the following types : * + Technical parameters — length, viscosity, etc. (dimensions) + + Psychological paramétres — taste, beauty, etc. (aesthetics) + +Time parameters — speed, life span, etc. + + Contractual parameters — safety, reliability, etc. + «Ethical parameters — honesty, integrity, nature, etc.are Benefits of maintaining quality in the construdigh a vy + Increase in efficiency because of quality consciousness " + Reduction of scrap/ clash due to less number of items being rejected + Easy identification of construction faults + Decrease in cost in the long run due to benefits of quality control * Creating quality consciousness in workers 20 're Se) 2 Best practices in QC in Construefi bs > Quality Control (QC) —- Depends on the contract but best ™%) practices require; * The Construction Contract defines the quality standards and the QC testing requirements. The contract requires that the QC testing lab be validated by the approved source. * The contractor must prepare a detailed quality control plan for each definable feature of work detailing how the quality standards will be achieved. The plan must be approved before work can begin.Construction QC Factors * 41. Human control: As the main activity part of construction process, the overall quality and individual ability of human will determine the results of all quality activities. So, human are considered as both the controlled targets and controlling motivation of other quality activities. (Cheng Hu) The contents of human control includes the overall quality of organization and individual's knowledge, ability, physical condition, psychological state, quality consciousness, behavior, concept of organizational discipline, and professional ethics.+ 2. Materials control: “y > Materials (including raw materials, finished products, semi- finished products, components and parts) are material conditions of construction, and material quality is one of necessary conditions to ensure construction quality. (Cheng Hu) Main contents of quality control of materials: * (1) Material procurement + (2) Material testing * (3) Storage and usage+ 3. Control of construction machinery and equipments: Construction machinery and equipment are: ¥v essential facilities for the modern construction, Y reflecting the construction power of the enterprise, and v having a direct impact on the project progress and quality. (1) The contractor should select construction machinery and equipment in accordance with advanced technology, economic rationality, production application, reliable performance and safety, with the applicability and reliability to a specific project.»~w OIA - s 4 ? > + (2) The performance parameters should be made sure correctly in accordance with the requirements of construction and quality assurance. + (3) Construction machinery and equipment should be regularly calibrated, so as not to mislead the operator. Besides, mechanical equipment selected must be matched with the adapting operation workers.Per ; + 4 Control of construction methods: a > 2 4 y 20 + (1) Construction program should be constantly refed > J and deepened with the progress of the project v4 construction. * (2) When selecting the construction program, some viable options of major projects should be prepared, presenting main contradictions, advantages and disadvantages, so as to discussion and comparison, then the best option will be selected. + (3) When developing programs for the major projects, key parts and difficult projects, such as the new structure, new materials, new technology, large-span, large cantilever, the tall structure parts, and so on, the possible construction quality problems and treatment should be fully assessed.+ 5 Environmental control: Creating a good environment will play an important role in guaranteeing the quality and safety of construction projects, achieving civilized construction, and setting social image of construction corporation. Control of construction environment includes not only the understanding, restriction, transformation and usage of natural environment, but also activities of creating working environment and environment management. (Cheng Hu)The method of quality control.’ A. Quality control by statistical methods: The use of statistics is essential in interpreting the results of testing of” a small sample. There are two types of statistical sampling which are commonly used for the purpose of quality control in batches of work or materials (Quality Control and Safety During Construction): wa : =e $ (1) The acceptance or rejection of a lot is based on the number of defective (bad) or nondefective (good) items in the sample. This is referred to as sampling by attributes. Inspect or test m pieces No Rectfy or detail (100% testinspect) the lot > € defective? Ship the lot te” s ” ”* (2) Instead of using defective and nondefective classifieat S A for an item, a quantitative quality measure or the cole measured variable is used as a quality indicator. This t tes procedure is referred to as sampling by variables.+ B. PDCA: + PDCA Cycle, which is composed of 4 stages of P (plan), D (do) , C (check), A (action).er , Quality Inspection “> 2 GIA + Inspection means the checking of material or productpt, ' various stages of manufacture or construction of an object. va + An inspection is a specific examination, measurement, testing, and formal evaluation exercise and overall appraisal of a process, product, or service to ascertain if it conforms to established requirements. v The results are usually compared to specified requirements and standards for determining whether the item or activity is in line with the target and tries to detect the faulty nature of the ruThree-Phase Inspection System aay | — Preparatory : Before the work starts the QC manager As! conducts a meeting to go over all the approved submittals, work plan, safety plan, etc with all parties involved in order to make sure the feature of work is ready to begin and makes sure everyone is on the same page. — Initial: As the work is beginning the QC manager conducts an inspection of the work to make sure the work is being performed as plan. The crew is working safely and with the correct material. — Follow-up: Throughout the work the QC manager conducts inspection as per contract and as requiredeS FACTOR AFFECTING QUALITY OF CONSTRUGHON 2 nw we Quality of construction is dependent, to a great extent, on: * +The quality of materials which are used in construction + «The expertise of workers + ©The technology adopted in construction + «Number, type and quality of inspections * + Quality consciousness of people+ Funds available for construction and quality control * Time available for quality control procedures + Existence of norms and guidelines for assessing quality of construction of a particular type + Experience and expertise of inspectors * Quality of design + Nature of the construction projectMAJOR ITEMS IN CONSTRUCTION JOB any _9 ag REQUIRING QUALITY CONTROL Per. Aw, 4 2a Quality of construction materials should be good. Guidelines should be followed in the assessment of quality of these materials. Some common materials which are used for construction are given below + +Cement + +Fine and coarse aggregates + +Chemical admixtures + + Timber + + Steel + +Soil of a site + + Bricks and stonesay © STAGES OF INSPECTION AND QUALITY CONTROL, @ 0) (1) Earth Work Stages: i + Measurement of dimensions in different directions in terms of ™) height, width and length vy + Excavation of soil + Determination of soil properties + Compacting soil Quality Control Considerations + Accurate measurements with precise instruments + Use of good equipment + Use of standard procedures for testing of soil + Use of equipment for compaction(2) Masonry Stages: + +Measurement of dimensions in different directions in terms of height, width and length + + Construction of masonry + + Curing of masonry work Quality Control Considerations + «Use of good quality materials + + Use of right construction procedures and correct bonds + +Employment of people with experience and expertise + +Adequate curing of masonryEr gy 3) Reinforced Cement Concrete (RCC) Stages: » 9 ? ca * Measurement of dimensions in different directions in termsiof. 20 ’ an height, width and length A » + Creation and installation of formwork + Provision of reinforcement + Mixing of concrete * Casting of concrete + Curing of concrete Quality Control Considerations + Use of good quality materials + Use of right construction procedures + Employment of people with experience and expertise * Correct detailing of reinforcement‘4) Sanitary and Water Supply Services Stages: + Measurement of dimensions in different directions in terms of length as well as area covered + Procurement of sanitary and water supply items + Installation of these items correctly + Testing of these items Quality Control Considerations + Use of good quality materials and items + Use of right construction procedures + Employment of people with experience and expertiseEr gy > » De 2. ) ; . m ¥ i 5) Electrical Services Stages: ae a) 7 + Measurement of dimensions in different directions in terms of length as well as area covered * Procurement of items + Installation of these items correctly + Testing of these items Quality Control Considerations + Use of good quality materials and items + Use of right connection procedures + Employment of people with experience and expertiseF eee YS Table: Various Effects due to Inadequate Quality Conia, es ‘Cause/Effect Ponding of Water Taking Place in a Slab Remedy/Precaution ‘The effect of ponding may be due to insufficient slope provided in the slab. This may create problems while washing floors. If ponding takes place in the topmost slab, it may be even more troublesome in the rainy season. Cause/Effect Cracks Appearing in Concrete Structural Members in a Structure Remedy/Precaution ‘The reinforcement detailing in the structural members of concrete should be correctly provided as a precaution. Ifthe cracks are detected, proper safeguards should be taken with the expert advice. In any case, cracks should be properly sealed so that corrosion of reinforcement inside does not occur. Peeling Off of Plaster, Crumbling of Concrete of Structural Members Remedy/Precaution Plastering of the surface should be redone in the area where the peeling ‘off has taken place. Fresh cover concrete from where crumbling of ‘concrete has taken place in the structural elements should be provided. Crumbling of concrete is considered as a falling hazard also. wy) 4‘Emorescence in Walls, Peeling of Plaster, Corrosion of Cement Plaster of the Walls ‘Remedy/Precaution Eflorescence may be duc to seepage in the walls. The sepage inthe walls should be arrested. Potions, where plaster has peled off, should be ‘replated. Wall portions where plaster bas lot its strength may be subject to guniting or may be reconstructed. ‘Walls of Great Thickness Showing Rupture, along the Length of ‘Wall in the Middle Portion ‘Walls may be provided with through stones or reinforcement bars going along the thickness of walls, This gives them safety i vibratory situations such as earthquakes. ‘walls having Less Strengths in certain Portions, such as Near Corners, Walls of Large Slenderness Ratio ‘Proper hond should be provided inthe walls, especially where wo walls, ‘meet. Wall of large slenderness ratio should be stengthened as under ‘earthquakes or under impact loads these may fil and cause accidents ‘Such walls may preferably be reinforced, ‘Leakage Due to Water Tank, Seepage at the Top of Mumty Slab Especially in Rainy Season ‘Leakage of water from the water tank should be arrested. Pipe joints should he checked and faulty ones shouldbe repaired. Murty slabs should he repaired 1 avid ponding of water. Falling Hazards Due to Parapet Walls and Water Tanks atthe Top ‘Remedy/Precaution ‘Parapet walls should be repaired to give them added strength. They may be rcinfored during reconstrction, The pillars of watcr tanks should Be ‘made of adequate strength so that they can take the shear stresses during earthquake conditions. ‘Seepage fram Water Tank Walls ‘The walls of the water tanks should be repaired stably Ferocement treatment may be given to the walls of tanks to make them impervious toDocument QC activities into a Management System which ©” > QC Document includes; O©MNAMARHWOD = . Non compliance Reports . RF Is (Request for information) . Change orders requests . Safety violations . Daily field reports . Test results . Permits . Close Documents . QA/QC plan - Testing programQuality Control Tools > IY a. The following are the most commonly used quality control ee . ; for a variety of applications to improve the quality process: 1. Cause-and-effect diagram (graphically display multiple causes with a particular effect) 2. Check sheet (indicate how often each item occurs) 3. Control chart (analyze variation in a process by comparing current data to historically determined lines) 4. Data collection 5. Flow chart (a process in sequential order)ey ¥ 0? The following are the most commonly used quality control tools» ; Quality Control Tools 42 for a variety of applications to improve the quality process: 6. Histogram (it displays how often the different values occur) 7. Pareto analysis (graphical representation of frequency of occurrence) 8. Pie chart 9. Run chart (to know the trend or changes in the average) 10. Scatter diagram (to identify potential root cause of problems and to evaluate cause - effect relationship) |1. The cause-and-effect_diagram is also called an Ishikawa diagram or fishbone diagram. It is used to organize and graphically display multiple causes with a_ particular effect. 2._A check sheet is a structured list, prepared from the collected data, to indicate how often each item occurs. tWIAD wy. + 3. The control chart is the fundamental tool- ‘of’, 7 statistical process control. It is a graph used to analyze variation in a process. By comparing current data to historically determined lines, one can arrive at a conclusion regarding whether the process is stable or is being affected by special cause of variation.r= a, @ NSN « 4. Data collection objectives are to + Identify the problem + Report the problem + Verify the problem + Analyze the problem * Correct the problem5. A flowchart is a pictorial tool that is used for representing a process in sequential order. Flowcharts can be applied at all stages of the project life cycle. 6. The histogram is a_ pictorial representation of a set of data. It is created by grouping measurements into cells, and it displays how often the different values occur. Frequency | nan Ageae. > gy. 2 QD. ae } 7. Pareto analysis is a graphical representation ft, 1 frequency of occurrence. Pareto charts are used to identify those factors that have the greatest cumulative effect on the system, and thus, less significant factors can be screened out from the process.8. The pie chart is a circle divided into wedges to depict proportion of data or information in order to understand how they make up the whole. The portions of entire circle or pie sum up to 100% 9. The run chart is a graph plotted by showing measurement (data) against time. Run charts are used to know the trend or changes in the average and also to determine if the pattern can be attributed to common causes of variation, or if special causes of variation were present. How Much Water Do We Use?ys we 5 . : , m3 4 + 10. The scatter diagram _is a plot of * vy variable versus another. It is used to identify potential root cause of problems and to evaluate cause - effect relationship. Scatter Plot No CorrelationeS Quality Assurance 3% 9 YIAD > 4 + In today’s workenvironment quality assurance is viewed a8 > %) an umbrella under which quality management activities take place and the owner’s primary quality assurance role is one of [Link] of the term quality assurance is now favored over the previously used abbreviation QAQC or QCQA. S sarr Quality Assurance Se SID ye + ASQ: “all the planned and systematic activities implerteeteti a ; within the quality system that can be demonstrated to provide confidence a product or service will fulfill requirements for quality.” + ISO 9000 (or BS 5750): quality assurance is “those planned and systematic actions necessary to provide adequate confidence that product or service will satisfy given requirements for quality.” + ISO 8402-1994: quality assurance as “all the planned and systematic activities implemented within the quality system, and demonstrated as needed, to provide adequate confidence that an entity will fulfill requirements for quality.”wer Quality Assurance ay <> 2 SID Oy + Quality assurance is the activity of providing evidence to cotabiahy J confidence among all concerned that quality-related activities are being performed effectively. All these planned or systematic actions are necessary to provide adequate confidence that a product or service will satisfy given requirements for quality. + Quality assurance covers all activities from design, development, production/ construction, installation, and servicing to documentation, and also includes regulations of the quality of raw materials, assemblies, products, and components; services related to production; and management, production, and inspection processes. + Quality assurance in construction projects covers all activities performed by the design team, contractor and quality controller/auditor (supervision staff) to meet owners’ objectives as specified and to ensure that the project/ facility is fully functional to the satisfaction of the owners/end users. ,r= Elements of QA > @ ) The elements of an acceptable quality assurance program” | include: . > = quality control by the contractor = acceptance sampling and testing and inspection = independent assurance = qualified personnel = accredited laboratories, and = a dispute resolution process. These elements work together to ensure an effective quality assurance program. Any elements missing from the program increase the risk of a reduced service life.ay Need For QC & QA In Construction: . 2 4, x 0 we | *Concern for project managers. Even minor defects in constructed facilities can cause heavy loss *Quality control during construction consists largely of insuring conformance to these original design and planning decisionswer ORGANIZATION FOR QC &QA 2% a IAD Y ren A variety of different organizations are possible for quality Soe a during [Link] common practice is to have two groups: [Link] quality control. [Link] quality assurance. + In large organization separate departments are formed. * Specific Individuals are assigned with these functions on small projects. + In both the cases project manager is concerned for the work.ams Construction Quality Control/Quality Assurance Organization ”y ; aarr » QUALITY CONTROL AND ASSURANCE PLAN, 2 LIA An inventory agency responsible for coordinating ¥ MS S QAIQC activities. A QA/QC plan should clarifies: * general QC procedures + Source category-specific QC procedures + QAreview procedures + Reporting, documentation, and archiving proceduresOJECTIVES OF QA PLAN te MD, So + Describe the quality program and organization , oe, ' implemented so that the project is constructed in accordance with the contract requirements and industry standards. + Describe guidelines for inspection and documentation of construction activities. + Provide reasonable assurance that the completed work will meet or exceed the requirements of the construction drawings and specifications.eS 7 2 QA Testing z Ps + The CQAO will be responsible for the QA mae sampling and testing program. * QA testing is provided for the verification of the adequacy and effectiveness of the contractor's QC testing.Quality Assurance Method ree Matrix’s i i ecepeeaton cuaiy asurace Matode ai Fel el el ( agi ele] ? 3/8/2//2/2/2/2)|2]s||5lé ReiastinaeeT xtc bebe bed ‘Authorized Material Source Uist Pepe | Pepe pe Pe] Pepe] Pepe ‘Authorized to Dever List xP} bebe] px x[x Proprietary Product or Process xP 1 pete x Tx ‘Manufactured to Natonal Quaity Standard x- [xx] x]x [px x] x ‘Commercial Qualty xf x |x x Department-Fumished Materials x|x[{x{x[x[x[]x x|x retabrication Audit Xx =x ‘Aurea Facity Audi Listing x|[x[x | Pepe] px aoe eb pete ee te famed tascace eel earl = xp pe pepe te Dee pe pp cone installer AppikatorErector Personnel x, betixpepe? UP [xp px Fabricator x[LxTx Tobepbe Seer epee oe a eo) : eee bee agree omen epee et eeQuality Assurance Method Application Matr “¥ Construction Method—Design ‘Construction Procedures—Engineer x x Fabrication Method—Design Fabrication Procedures—Engineer ‘ix Design/Job Mix Formula—Engineer Product Data Quality Control Pan—Engineer = =| x =P PT ‘Pre-Production Meeting x! Warranty ‘Warranty (Materials and Workmanship) Pl eb x| ‘Warranty (Performance) x| x! Mockups Pre Production Trial (Mockup) Quatity Control inspection, Sampling & Testing (Jobsite) inspection, Sampling & Testing (Source) Pre-Production Sampling & Testing (intial Stock) med el [ll fx] bell > >] >] >] [> “Sampling & Testing for Acceptance x] x] >] x] | |x|] =] [x |x|] x] [x |x|] x] [x Certncate of Compliance with Test Results x| x| Tnspection (Engineering) x| x! ‘Inspection, Sampling & Testing (Jobsite) Inspection, Sampling & Testing (Source) >| | >| > Inspection, Sampling & Testing (Verification) > [>| | | >| ‘Payment Based on Quality Factor Test Samples >] ] >| | ><] x] >< x| x] x] | x] x] x] x >| | pe] >] >] >] ><] [><] [>] >e] foe] [><] ><] [><] [><] >] ><] ><] > Lalan s 7 Why Quality Assurance Programs felt x ra ™% + —Starting site work without an acceptable, approved Quali Control Plan + —Inadequately developed Quality Control contract provisions + —Inadequately enforced Quality Control contract provisions + —Delay in submitting an acceptable Quality Control Plan + —Inadequate qualifications of personnel in the quality control organization + —Untimely or incomplete reports + —Failure to take corrective action when deficiencies exist + —Late or incomplete reporting of tests and inspections + —Lack of interest by contractors or management personnel.Table: lists the major work elements normally => performed by quality specialists. ~ > IY i, 4 ” 9 "S % Work Elements Reliability engineering Establishing reliability goals Reliability apportionment Stress analysis Identification of critical parts Failure mode, effects, and criticality analysis (FMECA) Reliability prediction Design review Supplier selection Control of reliability during manufacturing Reliability testing Failure reporting and corrective action system Process capability analysis Quality planning, Establishing quality standards ‘Test equipment and gage design Quality troubleshooting Analysis of rejected or returned material Special studies (measurement error, etc.)Write quality procedures Maintain quality manual Perform quality audits Quality information systems Final product inspection and test Receiving inspection ‘Maintenance of inspection records Gage calibration Vendor quality Preaward vendor surveys ‘Vendor quality information systems Vendor surveillance ‘Source inspection Source: Pyzdek, T. (1999). Quality Engineering Handbook. Reprinted with permission from Quality America, Inc.