School of Construction Management and Engineering

Management in the Built

Environment
Quality in construction projects
CE2CMB
Dr. Shabnam Kabiri
The journey today
❑ Why is quality important?
❑ What is quality?
❑ Quality standards
❑ The construction quality journey
❑ Continuous improvement
❑ Quality assurance vs quality control
❑ What can go wrong?

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Why is quality important
- The Home Builders Federation’s own satisfaction survey
shows a rise in customers reporting defects from 93% in
2015 to 98% in 2018.
- Poor quality is costing the industry annually more than
the combined profits of companies in the industry.
Research by Chartered Quality Institute (CQI) suggested
that better quality could save the industry between £7bn
and £12bn a year!

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Why is quality important
- 60% more chance of becoming injured during reworks
- Impact on people’s lives, livelihood and the reputation of
the industry
- Time to repair, lost opportunity, staff morale
- Today’s quality is tomorrow’s safety! (e.g. design)

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Why is quality important
“There is very little analysis done on costs and failure, yet
you are talking projects that are big money. The UK
construction industry is worth £100Bn each year, and if you
take just a conservative estimate of 1-2% as a failure cost,
you are talking of around £1Bn to £2Bn in the UK.” An
American study has found that 5-6% can be lost on defects.

(Source. CQI Cost of Quality Working Group)

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Why is quality important

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What is Quality

To try and keep it simple!

Meeting specification

Quality is about meeting the needs and expectations of

customers

Fit for purpose (obligation on us!)

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What is Quality

How can we assess quality, try and keep it simple!

One well accepted approach is FFF. Form, Fit and Function.

The quality attributes are split into 3 categories.

• Form. Dimensions, finish, material type, etc.

• Fit. How components fit together, gaps, interfaces, etc.

• Function. How something performs, typically measurable, etc.

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Quality Standards
System
ISO 9001:2015
International Quality Management
System standard.

• Can be applied to all industries

• Sets out a frame work for best
practice
• Advocates a process approach
• Standard is reviewed every 5 years
• Certificate issued by third party
• Valid for 3 years
• UKAS (UK accreditation Service)
backed

• Integrates with other standards

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ISO45001 9
Quality Standards
Product
BS EN 1090-2:2008
Execution of steel structures and
aluminium structures

Top level document that refers

to related standards. E.g.
Standards for structural carbon
steel and the Factory Production
Control certificate.

Product meeting this
standard will have a
Declaration of Performance.
Factory production
control.
Certificate issued
after 3rd party audit

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Quality Standards
Product
CE Marking (Conformité Européenne)
• Require by the Construction Product
Marking regulations
• Applies to all products where there is
a harmonised standard. (BS EN or EN)
• Self declaration process but must be
supported with relevant technical information. E.g. Test report
from an independent lab. UKAS accredited labs, give a degree
of reassurance due to them having to meet specific
requirements and degrees of accuracy
CE is not a mark of quality only that the item meets the
relevant regulations
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Construction quality journey

Specification
Validation
Design
Procurement

Build

Inspection

Testing

Commissioning

Handover

Aftercare

A well managed project have these elements being co-ordinated from Day 1

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Construction quality journey
Specification

• Normally produced by the clients designers

• Will be issued to align with RIBA stage depending on
contract
• Normally a set of specifications e.g.
• Architectural
• Structural
• Services
• Will refer to standards that must be read in conjunction
with the specification.
• Referred to by the contract and clearly define the clients
needs and expectations.

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Construction quality journey
Validation

• Level and types of validation will depend upon the scope of

works

• Refurbishment of existing building

• Dimension (Manual measurement or Point Cloud Survey)
• Services (e.g. Water quality, water pressure, Power
availability)
• Condition (Existing items that will affect the build or are
to be left in the finished job.)

• New build.
• Ground conditions
• Underground Service locations
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Construction quality journey
Design

• The amount of design is dependent on the contract

and the RIBA stage provided by the client.
• The design is developed by the designers / consultants
• Final design is often completed by the Sub-contractor
• This will included detail design for manufacture.

• Quality checks
• 3 D model clash detection
• Drawing review and approval
• Technical submittal
• Sample approval
• Bench marking

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Construction quality journey
How design can affect quality (Acoustic example)
Simple coordination elements
▪ Walls will achieve a certain dB
rating, however doors provide a
weak point / lower sound transfer
resistance
▪ The walls will have a different noise
attenuation than the floor and
ceilings.
▪ Any penetrations through the walls
for Building services will create
weak points for noise transfer
▪ Interfaces are the common causes
of defects and failings of systems
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Construction quality journey
Wall/ceiling/Floor specification (Acoustic example)
Complex coordination

▪ There will be a need for power and

IT/AV solutions for the rooms.
▪ Recessed sockets create weakness
▪ AV screens and speakers are often
recessed
▪ Noise transfer from room clusters
and adjacent tea points / corridors
need considering
▪ Room use – teleconference will
produce additional noise above
face to face meetings
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Quality Assurance and Control
Quality Assurance is not just out on site.
Clash detection using 3 D modelling

Cable tray clashes

with ventilation duct

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Quality Assurance and Control
Clash detection and coordination
Simplified through BIM technology

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Construction quality journey
Procurement

• Supplier pre qualification

• In house or third party
• Certification ISO / UKAS
• Competence
• Capability
• Capacity
• Experience
• Regular stress testing
• Dun and Bradstreet financial checks

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Construction quality journey
Build
• Quality planning
• Project quality plan / Inspection and Test Plan (ITP)
• Inspection and test plan for each package (By Sub-
contractor)
• Check sheets
All agreed before the work starts !
• Quality controls (Implementation of the plan)
• Off site inspection / Factory acceptance Test (FAT)
• Material certification
• On site inspection and testing
• Task specific training
• Inspection and test records
• Commissioning records
• Third party inspections
• Building
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Construction quality journey
Inspection

• Inspections conducted in line with ITP

• Self inspection / Self certification
• Hold point with main contractor signoff
• Hold point with main contractor and architect sign off
• Clerk of works inspections (main contractor or client)
• Building Control / Approved Inspector inspections
• Manufactures inspection / certification scheme

• Inspected against:
• Drawings
• Specifications
• Standards
• Benchmarks
• Manufactures installation standards
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Construction quality journey
Inspection/snagging and improvements

Defect / Snag Analyse data and look

capture on for trends
iPad Feed back to project

Share with
others Amend plans,
retrain etc.

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Construction quality journey
Testing
Commissioning
• Split between architectural / structure and services
• Specification / ITP defines performance requirements, or
refers to external standard. (e.g BSEN, BSRIA, IEEE, CIBSe)
• Testing and commissioning in line with test and
commissioning strategy that will typically be presented as a
test and commissioning schedule.
• Test are sequential
• First fix
• Second fix
• Commissioning
• Test are either self certified or witnessed.
• Test equipment must be calibrated for results to be valid.
• Final results and certificates are typically presented in the
Operations and
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Construction quality journey
Testing examples
• External laboratory tests. (ISO 17025 preferred).
• Heated / chilled water systems
• Potable water
• Air quality
• Concrete cube / mortar cube

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Construction quality journey
Testing on site examples

• Integrity testing
• Slump
• Electrostatic
• CCTV of drainage
• Air test

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Construction quality journey
Commissioning examples

• Commissioning covers a wide range of test types

• Electrical load testing
• Heat load testing
• Cause and effect
• Building Management System

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Construction quality journey
Handover
• Hand over should be planned from an early stage
• Defined as Practical completion
• Outstanding works and remaining defects defined and
completion plan agreed.
• O&M manuals, user guides etc handed over in advance
• BIM models and files handed over
• User training carried out before handover
• Critical to the user experience
• Warranties
• Product warranties
• Workmanship
• Collateral
• Government Soft Landing process for public sector works
• Be up to 3 years
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Construction quality journey
Aftercare

• Post completion needs to be effectively managed to ensure that

customer does not become disenchanted with the supplier.
• The Main Contractor is responsible for the resolution of
warranty defects
• Verification
• Arranging for remedial works
• The responsibilities vary depending upon the contract type.
• Concluded by the issue of the Making Good Defects certificate.
• This often releases final retentions.

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Continuous improvement

Process approach to Quality Management

Some times referred to as PDSA. ( Plan-Do-Study-Act )

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Continuous improvement

The construction process examples

Client specification
Act Plan
Remedial action Production of ;
Request for change Detailed construction programme
Design improvements Detailed design development
Retraining Quality Strategy
Material reselection Sample / Benchmark approvals
Project specific training

Contractor self inspection / test Procurement of products and

Factory acceptance services
Test witnessing Off site manufacture
3rd Party inspection / test Installation / Construction
Commissioning Change management

Check Do
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Continuous improvement

The construction process examples

Client specification
Act Plan
Make design or production Production of Benchmark
changes to ensure that schedule
product meets
requirements

Inspection of Benchmark Trade contractor

to ensure that it meets the produces
required standards Benchmark area

Check Do
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Quality Assurance Vs Quality Control

Assurance.
• all the planned and systematic activities implemented within the
quality system that can be demonstrated to provide confidence that a
product or service will fulfil requirements for quality

Control.
• the operational techniques and activities used to fulfil requirements
for quality

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Quality Assurance Vs Quality Control

Quality assurance examples

• Trade contractor pre-qualification process
• Design management
• Drawing approval
• 3 D Clash detection
• Trade contractor package scope (makes sure nothing is missed)
• Design verification
• Training and competence assessments
• Quality strategy plan
• Quality plan
• ITP production
• Systems audits / Third party audits

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Quality Assurance Vs Quality Control
Systems audit.
• Carried out by an independent trained person

• Confirms compliance with

– company systems,
– project plans,
– design specification
– relevant standards and legislation
• Documented report highlighting
– Non-conformances
– Opportunities for improvement
– Good practice (learning opportunity)
• Objective and evidence based.

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Quality Assurance Vs Quality Control
Example: Structural steel

Assurance (Verification)
• Structural engineers report
• A structural engineer should
verify that structural elements of the
design are safe and meet the relevant
regulatory standards.

Control (Validation)
• Weld integrity test
• Ultra sonic,
• Dye penetration
• X-ray/ NDT

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Quality Assurance Vs Quality Control
Example: Piling

Assurance (Verification)
• Geotechnical survey confirms
ground conditions
• Technical submittal for
proposed concrete mix.
• The piling Inspection and Test
Plan identifies each
characteristic that is critical to
the performance of the pile.
Control
• Concrete cube test
• Steel CARE certificate
• GPS location
• Integrity testing

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Quality Assurance Vs Quality Control
Inspection and Test Plan: Piling

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Quality Assurance Vs Quality Control
Inspection and Test Plan: Piling

• Records are kept in line with the

ITP. E.G.
• Concrete cube test result
• Test in accordance with
EN 206-1 2000 Slump
• 28 Day test in accordance with
BSEN 12390-2 2009
• Tests by ISO 17025 / UKAS
Certified lab.
• Test certificate is part of
quality record.

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Quality Assurance of Materials
Ensuring that contractors provide an evidence trail
demonstrating the provenance of the material is a good
start .
• This could be
• A declaration of conformity (CE)
• Invoices from manufactures
• Test results from an independent lab
• Physical marking where practical
• FSC marking and documentation for Timber

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Quality Assurance of Materials
What can go wrong

Poor communication.
• The guys in the suits don’t talk to the guys in the boots.
• Result, wrong drawings, wrong materials, not to standard etc.

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Quality Assurance of Materials
What can go wrong

• Poor materials.

• 2 bolts sheared and

fell into a public area.

. Root cause. Hydrogen

embrittlement.

• All similar bolts had to

be tested

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Quality Assurance of Materials
What can go wrong

Initial
estimated cost
£6M

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Quality Assurance of Materials
What can go wrong

• Supporting cables
failed during
construction

• The deck fell at 8.30 in

the morning.

• No workers were
under the deck at the
time

It could have
been fatal.
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Quality Assurance of Materials
What can go wrong

• The end wall of a school

collapsed.

• The cause was poor

workmanship.

• 17 schools closed. 72 found

with defects.

• No children were injured but

It could have been

fatal
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Quality Assurance of Materials
What can go wrong
Poor design management / coordination.

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Quality Assurance of Materials
What can go wrong

Poor specification.
Design and Build “Employers Requirement” (ER) asked for “Single drainer
stainless steel sink”.

The contractor provided the cheapest from the local supplier for £40

The client really wanted a high specification Franke that cost £250 !

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