Professional Documents
Culture Documents
QAQC Plan
QAQC Plan
QAQC Plan
P Ashraf Taha
PROJECT NAME
DOCUMENT TITLE
Rev: 0
QAQC PLAN
Date 7/29/2018
TABLE OF CONTENTS
1.1 INTRODUCTION……………………………………………………………………………………..………….5
1.2 SCOPE………………………………………………………………………………………………….……………5
1.3 QUALITY MANAGEMENT APPROACH………………………………………………….…………….5
1.4 REFERRENCE DOCUMENT…………………………………………………………………….…………..6
1.5 ABBREVIATION…………………………………………………………………………………….……………7
1.6 QUALITY OBJECTIVES…………………………………………………………………………….………….7
1.7 QUALITY CONTROL……………………………………………………………………….……..….………..8
1.8 QUALITY ASSURANCE…………………………………………………………………….……..….……….8
2.0 QUALITY POLICY & ISO CERTIFICATES…………………………………………….……..….………..9
2.1 QUALITY POLICY………………………………………………………………………….……...……….9
2.2 ISO CERTIFICATES………………………………………………………………………….…………...10
3.0 QUALITY SYSTEM………………………………………………………………………………….……….….11
3.1 QUALITY SYSTEM………………………………………………………………………….………….…11
3.2 DEGREE OF QUALITY SYSTEM……………………………………………………….…………….11
3.3 WORKS PROCEDURE AND INSTRUCTION………………………………………….………...11
3.3.1 QUALITY PLANS…………………………………………………………………….........11
3.3.2 SUBCONTRACTORS………………………………………………………………….……12
3.4 PROJECT ORGANIZATION PLANS COMMUNICATION
AND RESPONSIBILITY……………………………………………………………………………..….13
3.4.1 ORGANIZATION AND COMMUNICATION………………………………….……13
3.4.2 RESOURCES & COMPETENCIES…………………………………………….…….….13
3.5 KEY PERSONNEL & RESPONSIBILITY………………………………………………….………….14
4.0 PROCEDURE…………………………………………….…………………………………………….…………..17
4.1 PLANNING PHASE…………………………………………….………………………………………....17
4.2 DOCUMENT CONTROL………………………………………………………………………………...18
4.3 ENGINEERING …………………………………………….………………………………………….……18
4.4 PURCHASING …………………………………………….………………………………………………..19
4.4.1 PURCHASING REQUIREMENTS WILL CONSIST OF (LPO) …………………19
Page 2 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 4 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
1.1 INTRODUCTION
1.2 SCOPE
The Scope of the Project Quality Plan is designed to provide a common framework
for an effective execution of the structural steel, which has been manufactured,
fabricated, painted and erected by Gulf Steel Engineering for Project: “Al-Maha
Center for Children and young Adults within Al Wakra Hospital Campus” as
per specific responsibilities, work instructions and project specification quality
management system throughout the project.
This framework is the project’s quality benchmark in order to provide high quality
products and processes by identifying the basis for reviewing and auditing of the
products and activities to verify that they comply with applicable procedures and
standards and to assure that the deliverables quality is according to the contractual
requirements emphasizing the project quality management role that governs the
decisions and instructions concerning project quality.
The PQP shall describe the means and methods for ensuring satisfactory materials and
workmanship, including the following preparation
Procurement, maintenance
Calibration of testing equipment and supplies needed for inspection,
measurement, and tests
Conformance of all raw materials to project requirements.
Handling, shipping, receiving, storing of the Raw materials
Joint Preparation and use of welding procedure specifications (WPSs)
and control of welding consumables.
Use of the latest approved version of shop drawings and approved
fabrication procedures
Proper performance of non-destructive examination (NDT) by approved
third party
Page 5 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
The approach for ensuring the appropriate Quality Management conducted by the
Project Management, this includes all activities of Quality Management that
determine the quality policy, objectives, and responsibilities and implements them by
means such as quality planning, quality control, quality assurance, and quality
improvements.
The project’s Quality Management approach adheres to and includes work activities
in support of the following quality management processes sequence:
Document Description
Rev: 0
QAQC PLAN
Date 7/29/2018
1.5 ABBREVATION
Page 7 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
QUALITY OBJECTIVES: -
The goals of Gulf Steel Engineering, with regard to quality assurance are as follows
1
1.5
The development of this document shall ensure requisite quality
management and adoption of a ‘Right First Time’ every time with
‘Zero Defects’ culture.
To meet the specified requirement of the client.
To complete all the work within the agreed construction time at good
quality.
To maintain the executed works with in the maintenance period as
per the agreed contract.
To expand our business by offering the best in quality, cost and
program.
GSE shall ensure that the fabrication and installation of the project
shall be able to achieve design
Page 8 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Ensure that the work shall also be governed by the main contractor
quality policy and key performance indicator.
Ensure that the work shall also be governed by the end user policy.
Measuring performance and continuous improvement.
Conduct operations in conformance with all applicable environmental
laws and regulations of the jurisdictions in which we do business.
To ensure APPROVED status is achieved for the first time submission of
documents.
1.7 Quality Control
Quality Control (QC) personnel role is performing inspection accompanied by
documentation of the work product deliverables throughout the life of the project as
stated in the project ITP meanwhile the material receiving, fabrication, to the product
finalization the ITP and the detailed work procedures with its acceptance criteria; has to
be subjected to the GSE QA/QC and Client approval ensuring that; all these starting
documents completely cover and capable to verify compliance with the
contractual/specification requirements.
QC must assure the:
Page 9 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 10 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
1.
1.1
Page 11 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 12 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 13 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
1.2
This project quality plan can be updated and or revised to suit each particular contract and or
quality assurance system to be followed. Any amendment or updating to this plan shall be
discussed among the project quality team of client and project management / quality team to
consider the reviewing parties, approval of the amendment shall be made by our client and
revision of the quality plan will be prepared. Each amendment will be serially numbered as
next latest revision, entered on the amendment sheet and distributed to all holders of the
plan. Each amendment will outline the new procedures to be followed for that particular task
and to be discussed by the QA/QC Engineer among project construction team.
Each amendment shall be recorded in the amendment file, which shall be distributed to all
holders of the quality plan.
GSE Company Pledge of Quality declares our commitment: "GSE employees will always
respect our customers' viewpoints in striving to deliver product quality and customer service
that exceed their expectations." To this end, GSE promotes continuous, decisive efforts to
enhance product quality and to reinforce its quality management system.by specific
requirement of QCS 2014 and project Specification.
In order to efficiently and effectively perform their jobs, employees must have a clear
understanding of their roles and responsibilities within their organization and the existing
documented quality management system and how their efforts contribute to the achievement
of the goals and quality objectives. The Projects (and /or Contracts) vary in size and
complexity so; this does not imply higher or lower standards of workmanship but indicates
the amount of supervision, inspection, testing and documentation to ensure the specification
is met.
To exert effectiveness, client shall ensure that design and development for the related works
is properly planned, with its input and output properly reviewed and any changes shall be
fully validated to conform to the project requirement. GSE on its part shall be fully
responsible for the success of the work by having its project personnel perform the works in
accordance with the approved.
Page 14 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Method statement submitted for this project shall be documented, where procedures are
included as appendices to this quality plan.
2.
3.
3.1
3.2
3.3
3.3.1 QUALITY PLANS
Quality plans are used on each project to implement the quality system and include the
following:
Page 15 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Where GSE used subcontractors they are to comply with the GSE quality system and
quality work procedures unless they can demonstrate that their quality system is
acceptable to GSE as per project requirements and project spec. The Quality
Assurance Department, who directly reports, and is not conditioned by production or
delivery problems, is responsible for monitoring, verifying and documenting the correct
implementation of the project requirement.
Gulf Steel & Engineering shall cooperate and coordinate with his Client in all matters
relating to the quality control procedures and all personnel directly involved in this
project shall be continuously kept informed of contract requirement and work
procedures.
EMPLOYER
EMPLOYER
ASSISTANT
Rev: 0
QAQC PLAN
Date 7/29/2018
GSE ensure that the qualification requirements (such as education, skills, training,
experience) for each job are identified, determined and documented in job descriptions.
Training is provided to employees or other actions are taken in order to meet defined
qualification requirements. The effectiveness of provided training or of related actions is
evaluated. Any candidates that will qualify will be called on for technical interviews
GSE ensure that designated person assigned for a specific task has the ability to perform
the job efficiently, has related knowledge, abilities and qualities that can be used as standard
against which the job and performance is measured in accordance with his designation.
Authorized Representative
The GSE designated QA/QC Engineer / Quality Inspector shall be the person in charge for
all related Gulf Steel & Eng. site QA/QC activities and inspection as per the approved ITP.
Execution of the works on site as per the project specification and quality standards shall be
the responsible of Gulf Steel & Engineering constriction team under the direct supervision of
client.
Operation Manager:
Project Manager:
Page 17 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Production Manager:
Planning Engineer
Prepares and submits master program of the project in consultation with Project
Manager.
Prepares and submits Planning Data’s to be incorporated to the submittal of
Project Progress Report (weekly/ monthly) in coordination with Project Manager
and Site Quantity Surveyor and submit same to the Consultant / Client for
Approval.
Submits planning report such as preparation of manpower requirements for the
project, preparation of material procurement report in accordance with approved
program.
Prepare and update project schedule based on the contract.
Coordinate with Project Manager the effective implementation and monitoring of
Look Ahead-Schedule including the project actual accomplishments.
Participate in project meetings and discussions with the Client as required.
Page 18 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Reports to the Project Manager the status of project progress against the plan
schedule and provides corrective actions necessary if the planned schedule is not
achieved.
QA/QC Manager:
QA/QC Manager shall coordinate with Client on all stages of work as per the ITP
and the implementation of QCP
Maintain all quality records
Conduct inspection and monitor the required tests
Determine and report any NCR and recommend corrective actions.
Ensure that all personnel should be fully aware with the all quality requirements
and Application for all quality documents as relevant to their discipline
Ensure appropriate supervision control of all work activities so that all quality
related operations are effectively covered.
Rising of relevant Request for Inspection and transmission to Quality Department
before the scheduled inspection or test.
Assigned to assure and to plan that all the clients' requirements and workshop as well as the
site quality activities are fulfilled through the QC personnel according to the approved quality
control plan through:
QA Engineer
Assigned to assure that the project processes are complied with Gulf Steel & Engineering
quality management system and verifies the proper execution of the project quality activities
through:
Page 19 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Verify the Review of the final documentation” Final Book” before hand over to the
Client.
The Document Controller is responsible for the receipt, control and distribution,
and revision control of all technical documents and drawings pertaining to project.
Coordinate with the Contractor’s DC in controlling and preparing the Documents
Coordinate with contractor’s QA to ensure the proper filing system is implemented.
Welding Inspector:
To be fully aware of the Day to day Inspection program for structural steel works in
advance so that he can raise the RFI in a timely manner.
To attend all inspection / Witness points in a timely manner and records the
results of his inspections on the appropriate forms.
Completion and filling of all inspection records under his responsibility and
reporting to QA/QC Manager.
Supervisor / Foreman:
Assist the QA/QC Coordinator to execute and maintain overall quality of the work
on daily basis
Be directly in charge in the execution of activities
Ensure also that the working area is safe for the workers and equipment’s
Ensure that tool box talks are conducted as per HSE plan
Assist in the implementation of this Project Quality Plan.
Provide required training for the site personnel involved
Ensure availability of required tools to maintain a safe work place
Ensure compliance with procedure respect to equipment’s and related
certifications and permit.
Responsible for achieving installation goals specific to their location for all GSE on
site or off site projects
Provides overall direction of Field Service coordinator in support of departmental
objectives
Reviews performance; addressing escalated issues and resolving problems
concerning installation
Assists General Manager and project manager by providing technical clarifications
concerning installation
Complies with management reporting and communications as requested
Page 20 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Ensuring that the equipment & instruments used for construction and day-to-day
temporary activities are of high quality and complies with company, industry and
government authority standards.
Ensures that all resources like manpower, machineries, materials and equipment
are made available for undisturbed site activities and are allocated wisely.
Carries out supervisory responsibilities in accordance with the organization's
policies and applicable laws.
Works with multiple departments regarding installation related project.
4.0 PROCEDURES:
The review of contract requirements containing specific quality requirements, against requirements
are the responsibility of the designated project manager.
A project specific Quality Plan will be developed by GSE Project Manager, based on contract,
engineering drawing and specification requirements, to assist in planning, receiving, inspection and
in process inspections.
Manufacturing and quality operation procedures and work instructions shall be created prior to
manufacturing. Aconex is used to provide list of Documents that have been uploaded as per
Contract requirements.
Kick-off Meeting
Prior to Fabrication meeting per project shall be convened to ensure all departments are
knowledgeable of contract requirements.
End of project we sort and inventory of goals accomplished and lessons learned from the completed
projects. Now is the time to carve out a few hours with your QA/ QC and Development teams to
review the achievements.
Drawing and specification used to control the fabrication, processing, Erection and site work of
contract deliverable items will be controlled and documented in accordance with the following,
and entered Drawing Index and Status Log:
Distribution of drawings
Page 21 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
4.3 Engineering
Detailing shall be responsible for producing all shop and erection drawings as required
by the contract. It shall be the drafting department responsibility to produce copies of
shop drawings for Approval. Upon receipt of contract drawings Detailing shall record
date of arrival, contractor’s name, job title, and number of addendum’s received.
Drawings will clearly note any special instructions. Detailing shall be done per contract
documents. Welding symbols per project specification.
Upon completion of shop drawings, the number of copies required by the specifications
will be printed and forwarded to the Client for review and Approval. When approved shop
drawings are received back from client, Detailing will check Notes. They will review the
drawings and make any corrections as noted by the client. When completed, the
drawings will be passed to the workshop for fabrication and procurement.
The design drawings for shop use with the intent of supplementing the AISC standard
manual. The detailer shall be familiar with the QCS 2014, BS 5950, steel detailing
specifications, shop practice and field erection procedures.
Rev: 0
QAQC PLAN
Date 7/29/2018
4.4 Purchasing
Purchasing responsibility:
Project management is responsible for the purchasing of the materials, services
and processing of contract deliverable items. Purchasing is accomplished by the
project manager. It is the policy that all material and services required for the
project to confirm the contract requirement.
4
4.1
4.2
4.3
4.4
4.4.1 Purchasing requirements will consist of (LPO): -
a) Grade of Material
b) Specification
c) Quantities
d) Sizes
e) Identification marking requirements
f) Certification requirements
g) All structural steel material should be approved by Contractor and Client prior to
procurement.
Page 23 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
The process is utilized for evaluating the Suppliers based on their ability to supply the right
product at the right time in conformity with the specifications and compliance of all
documentation process as per the rules to optimize the total quality of the Procurement
Planning process;
a) Record the defective or the damaged supply if any against each LPO/MPO/ to find
out the cost of defective supply
b) Quality of work and additional another features.
c) Time schedule commitment,
d) Project Specification commitment
e) Environmental and Safety rules commitment
f) Manpower/equipment performance
g) Delay (processing time -dispatch date).
d) The Project Manager will contact the Client for any detected discrepancy; if the
materials supplied by the Client.
Page 24 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 25 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
e) Planning Head use the material weekly status report for the preparation of project
weekly progress in accordance with approved project plan and send to client.
Types and diameter against the purchase order and the accompanied Mill
certificates.
All damaged packages shall be rejected and returned back to the supplier.
One package from each shipment shall be randomly chosen to weld a test
specimen to check:
Fusion of completed weld (visually).
Appearance of completed welding consumable (visually):
Page 26 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 27 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Monitoring and measuring equipment are used and controlled in a manner that ensures
continuing suitability; this includes ensuring that the environmental conditions are
suitable for the calibration, inspections, measurements and tests being carried out.
We also define the processes employed for the on-going calibration, control and
maintenance of monitoring and measuring equipment including their identification,
location, frequency/method of checks, uses/acceptance criteria and the action to be
taken when results are unsatisfactory.
All monitoring and measuring equipment that can affect work quality are identified
and calibrated at prescribed intervals against certified equipment having a known
valid relationship to internationally or nationally known standards. Where no such
standards exist, the basis used for calibration is documented. The external
laboratories used for inspection, test or calibration services are selected, qualified.
When monitoring and measuring equipment are found to be out of calibration (or
when calibration status is not known), they are adjusted or re-adjusted as necessary
and the validity of previous measuring results is documented; actions taken are
documented, including appropriate corrective actions to remedy the situation and
preclude its recurrence.
All measuring and monitoring equipment’s and inspection tools shall have valid
calibration during inspection as per the project specification and the calibration
records will be maintained through calibration log register as client requirement.
All welding machines and inspection equipment’s are periodically calibrated (Yearly).
Individual equipment’s have serial number for identification
All calibrated equipment should be registered and maintained in the GSE template.
All members of staff are responsible for notifying the Quality Manager of any
identified non‐conformances.
A copy of the NCR is forwarded to all responsible managers that are involved in
the scope of works related to the NCR, for information and action.
The Quality Manager is responsible for the completion of Non‐Conformance
Reports and for determining and implementing corrective action.
Once the corrective action has been completed the Quality Manager is to
undertake a verification check to ensure that corrective action has been effective.
Minor & Major Nonconformity
Page 28 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Minor nonconformity – Any nonconformity which does not adversely affect the
performance, durability, interchangeability, reliability, maintainability, effective use
or operation, weight or appearance (where a factor), health or safety of a
product. Multiple minor nonconformities when considered collectively may raise
the category to a major or critical nonconformity.
Major nonconformity – Any nonconformity other than critical, which may result in
failure or materially reduce the usability of the product for the intended purpose
(i.e. effective use or operation, weight or appearance (where a factor), health or
safety) and which cannot be completely eliminated by rework or reduced to a
minor nonconformity by an approved repair.
Repair Non-Conformity
The corrective actions for NCRs shall be discussed and agreed with the contractor within 14
Days. The NCRs shall be closed within 30 days or the closing date shall be agreed with the
contractor.
Controlling Nonconformities
All relevant documentation to this procedure such as NCRs and registers. If the NCR cannot
close within 30 days, GSE shall propose the corrective action and the new target closing
date shall be discussed with contractor and the updated register with the new target date
shall be submitted to the contractor.
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 30 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 31 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Qualification of welders:
The name of the department or position responsible for administering and
maintaining documentation on the qualification test program.
The extent to which independent testing laboratories will be employed in
qualification.
The extent to which the QC department will be involved in qualification.
QC Engineer selecting and testing qualification plates, authentication of test reports,
and the disposition of specimens.
Appropriate forms and records
Master list of qualified welders, welding operators, and tack welders
Renew the welder certificates every six months by evaluating the welder
performance by supervision Engineer.
The certification shall remain valid providing it complies with the conditions for re-
approval of certification specified in BS EN 287 Part 1.
Welder testing shall be witnessed and certificates endorsed by an independent
Inspection Authority (Supervision Engineer)
Qualification actions taken when new welder are joined in workshop.
Make all welder qualification test results available for the Client’s review.
Prior to start any welding activity Welding Procedure Specification (WPS) and
Welder shall be approved by client.
4.5.10 FABRICATION:
The purpose of this chapter is to emphasize the quality measures of the fabrication
process throughout the execution of the project from the prefabrication stage till the sand
blasting and painting before the release to site.
Preparation of Material
Plate quality, with notation of surface and internal defects and repair
Page 32 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Punching is permitted without the conditions of this Part, provided that the holes are
punched at least 2 mm less in diameter than the required size and the hole is reamed to
the full diameter after assembly.
4.5.12 Fitting
Built up Columns steel structural shall be assembled in jigs or on suitable surface plates
with proper layouts as per the drawing. Column bottom plate will be kept at bottom and
side’s two vertical plates will be fit up with the bottom plate by means of Butt weld joint.
Stiffener plates will be provided at least every 1 meter to avoid the distortion and to
maintain the built up box column sizes & shape. The top plate shall be fit-up with this two
plates and complete the fit-up of Built up box column by tack weld. After completion of
full built up box column joint fit-up, S/C GSE QC Inspector will check the fit- up and
release for welding. Such as,
4.5.13 Marking
The marking of pieces, as well as the position of such marking on the piece, to be
carried out in accordance with the erection drawing applicable and include the
information stated therein. when the drawing does not mention the marking position
on the piece, this will be obviated by issuing a document and / or sketch drawn up at
the time of marking providing sufficient information for the retrieval of the marking
itself.
All parts shall be marked with a punch so that every piece has the assembling
references.
The retrieval of the marking on large size pieces shall be made in the site without
need of handling.
Page 33 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
4.5.15 Welding
General Requirement of Visual Inspection
Weld visual inspection shall be carried by fabrication engineers or certified welding inspector
as per approved standards for external defects like, surface porosity, under cut, excess
penetration, and overlap, lack of penetration or incomplete fusion and fillet sizes.
All dimensions shall be recorded in approved format. 100% visual inspection shall be carried
out for external defects. If required client QA/QC shall conduct the final inspection and
review all inspection reports and prepared as inspection and test plan (ITP).
Page 34 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
SN .
TYPE
No ALLOWED DEVIATION
1 Length
(Length after cutting)
2 Curved or Cambered
3 Position of Fittings
(Critical joints only)
4 Position of Holes
5 Squareness of Section
6 Flanges
Plate Distortion
7
Page 35 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
8 Web Distortion
Magnetic particle testing procedure shall be in accordance with approved Standard. The
Evaluation of indication and the acceptance criteria shall be in accordance with approved
standards. Independent testing authority MPI reports shall be obtained for fillet welds.
The ultrasonic testing of plates for lamination shall be in accordance with SA 435 and UT of
Butt joint shall be in accordance with approved standards. Independent testing authority UT
reports shall be obtained for all butt joints.
Review and approve the qualification documentation of those performing NDT. NDT
personnel Qualified to a minimum of ASNT Level – II.
Witness NDT, review the test results, and verify that reports are complete and
legible.
Calibration of Equipment to be maintained and it should be available during request.
Rev: 0
QAQC PLAN
Date 7/29/2018
All results of any inspection shall be thoroughly documented in writing to verify that the
specified requirements have been met. Future maintenance or the removal of a failed
coating system may be dependent on the factual reporting of every phase of the work.
The fabrication at shop should be so planned that units to be handled weigh nearly the
same. The erection drawing should reach the site of construction well in advance to plan the
erection sequence and material handling. Erection should be carried out with the help of
maximum possible mechanization by using tower crane or mobile cranes.
Page 37 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 38 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
6.0 ERECTION
The purpose of this chapter is to emphasize the quality measures and surveys of the erection
and installation processes at site throughout the execution of the project from the receiving of
the fabricated material at site till the erection and installation. GSE scope at site
The painting structural after fabrication shall be protected from further damage during
transportation. The materials will be loaded on the trailers using timber supports and
separators and secured properly to prevent any damage to the material while transportation
to site.
Fabrication items will be delivered loose. Minor fabrication items, which are not likely to be
subject to permanent deformation during handling operation (i.e. bracing etc.) may be
bundled or hoped. Small items (i.e. bolts, loose, cleats etc.) will be packed in crates / drums
or loaded on pallets.
The erection process requires considerable planning in terms of material delivery, material
handling, member assembly and member connection. Proper planning of material delivery
would minimize storage requirement and additional handling from the site storage,
particularly heavy items. Erection of structural steel work could be made safe and accurate if
temporary support, false work, staging etc. are erected. Before erection the fabricated
materials should be verified at site with respect to mark numbers, key plan and shipping list.
The structural components received for erection should be stacked in such a way that
erection sequence is not affected due to improper storing. Care also should be taken so that
steel structural components should not come in contact with earth or accumulated water.
Stacking of the structures should be done in such a way that, erection marks and mark
Page 39 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
numbers on the components are visible easily and handling does not become difficult. From
the earlier discussion it should emphasized that safe transportation of fabricated items to the
site, their proper storage and subsequent handling are the pivotal processes for the success
of fabrication of structural steel work.
Arrival storage Area: For the materials when they are off loaded from the trucks and
registered. The materials will be inspected at this location and certificates of release at the
factory will be reviewed. Materials that need repair work will be tagged and repaired at this
location.
Main storage Area: For the materials which has its QC acceptance and considered ready for
erection.
Quarantine storage: Where the quarantined materials will be kept. Issue NCR for these
materials and send it back to workshop for rectification.
Page 40 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
It is planned to provide materials in site required for enough days’ erection according to the
project erection plan. Proper contacts will be made with the factory to ensure proper flow of
materials to avoid shortage of materials or excessive storage of materials over the capacity
of storage area.
A variety of methods can be employed for the erection of a structure. Normally, the
selection of the method is influenced by the type of the structure, site conditions,
equipment, quality of skilled labor, etc. available to the erector. However, regardless
of the method adopted the main aim during erection is the safety and preservation of
the stability of the structure at all times. Most structures which collapse do so during
erection and these failures are very often due to a lack of understanding on
someone's part of what another has assumed about the erection procedure. Hence,
it is emphasized that as far as strength and stability of the components during
erection are concerned, they must satisfy the provision of QCS section 16 and AISC
standards. For the guidance on general fabrication and erection of structural steel
work, QCS section 16 must be followed. Before the commencement of the erection,
all the erection equipment tools, shackles, ropes etc. should be tested for their load
carrying capacity. Such tests if needed may be repeated at intermediate stages also.
Thus quality control must start from the setting out of the foundations and the holding
down bolts. This operation is often done at a stage when site conditions are
disorderly and most untidy and the environment appears to be incongruous to
accuracy. However, inaccuracies in marking the center lines and the levels of
foundations allowed at this stage are likely to cause misfit in the connections and
misalignment of the structure leading to secondary stresses in the members. In such
areas corrective measure must be taken by way of locally modifying some of the
components so as to eliminate the mismatch
Bracings
During the entire erection period, the steelwork should be securely bolted or
otherwise fastened and braced to take care of the stresses from erection equipment
or the loads carried during erection. In addition to this, adequate provisions to resist
lateral forces and wind loads during erection should also be made according to local
conditions. Normally bracings are built into all types of structures to give them a
capability to with stand horizontal forces produced by wind, temperature and the
movements of crane and other plant in and on the building. Bracings can be
permanent or temporary.
Page 41 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Temporary bracings required at some stages of the work must have properly
designed connections and should be specifically referred to in the erection method
statement.
The decision on sequence of erection such as which member should be erected first for
providing initial stability to the structure or whether temporary bracings should be used
for this purpose should be taken at an early stage of planning of the erection process.
The best method of erecting a structure within the acceptable tolerance limits is to make
sure that accuracy is achieved from the very beginning of the job
2 Vertical Wall
Deviation from exact position at
steelwork support point
Page 42 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
Page 43 of 45
GSE-PQP-2018-001
Rev: 0
QAQC PLAN
Date 7/29/2018
6.6 Joints:
Most steel structures are fabricated by either bolting or welding in the shop and bolting or
welding in the field. Durability of a structure largely depends on the quality of the joints made
at site.
6.6.1 Bolted connections:
Should be ensure that all parts intended to be bolted together should be in
contact over the whole surface and the surfaces should be thoroughly cleaned
and painted with specified primer paint and the two matching plates or sections
secured together while the paint is still wet by service bolts. After erection, the
joint should be made by filling not less than 50% of the holes with bolts.
The service bolts are to be tightened. The holes that need enlargement to admit
the bolts should be carefully examined the extent of the inaccuracy and the
effect on the soundness of the structure. Such holes must not be formed by gas
cutting process.
The bolts contact surfaces the material surfaces should be absolutely free from
grease, lubricant, dust, rust etc. and shall be thoroughly cleaned before
assembling. The nuts should be pre tensioned by a torque–wrench or by the
turn of the nut method with the help of pneumatic tools. In the case of
connections such as base plate they must be aligned and levelled using
wedges/ shims and subsequently filled by grouting.
Revised set of drawing will submit by a GSE upon completion of a project or a particular job.
They reflect all changes made in the specifications and working drawings during the
construction process, and show the exact dimensions, geometry, and location of all elements of
the work completed under the contract. Also called record drawings or just as-built.
Rev: 0
QAQC PLAN
Date 7/29/2018
After completion of final alignment inspection and bolt tightness verification of the erected
structures, RFI will be raised for final inspection to the client.
All the stage wise inspection will be carried out as per Approved ITP. Erection group will perform
survey works to ensure that erected works are within tolerances specified in project
specifications. Grouting under base plate will be allowed only after erecting main elements; fully
tightened their connections and ensuring that tolerances in verticality and alignment is within
acceptable range.
Final inspection will be carried out with concerned parties, documentation will submit for the
handover.
9.0 SUMMARY
This PQP explains the importance of fabrication and erection in structural steelwork is
underlined. The various tasks involved in fabrication are discussed. The joints, which are
important components in structural steelwork, are explained, with a special emphasis on welded
joints. Some aspects of erection of steel structures are also presented.
Page 45 of 45