The PWD Quality Control Manual is prepared to provide a base document to effect quality control in construction of projects undertaken by Kerala Public Works Department. This is intended to enable the engineers and supervisory staff to check the different activities of construction with reference to the quality aspects and ensure that standards envisaged are achieved.
Quality control tests have been made mandatory for projects undertaken by state PWD from 1.9.2014. Clause 2401and 2406 of Revised PWD Manual2012 stipulates that PWD shall follow a three tier quality control system for ensuring quality of projects executed. This includes technical audit after completion of construction.The system envisaged is as below,
Second-tier QC checks/tests are to be done by the QC wing of PWD on a random basis. However,it is desirable that the QC wing does quality control tests for all major and important items of construction.The frequency of tests shall be as given in this Manual or as specified in the Contract The QC wing is authorized to inspect all projects undertaken by PWD, including maintenance and repair works, irrespective of the estimated cost and conduct quality tests. Results of the tests so done shall also be recorded in the QC module in PRICE software.As far as possible, results shall be forwarded through e-mail to the Executive Engineer with copies to the Assistant Executive Engineer and Assistant Engineer within the minimum time required for carrying out he test.
As per clause 2406 of the revised PWD Manual 2012, Technical audit shall be done by an external agency/expert empanelled for the purpose after the construction of a project is completed. This will form the third tier of QC system.Technical audit shall be done for projects, estimated cost of which is above Rs5 crores.All tests carried out in the first-tier and second-tier QC testing shall be reviewed during technical audit.Technical Audit shall be completed within six months from the date of completion of construction. Non-destructive testing techniques shall be adopted if conventional testing techniques cannot be applied
i)The laboratory must be able to choose and apply the test method that provides a technically correct answer to the problem.
ii)The testing must be performed efficiently, also in such a way that delivery times can be met and costs and charges minimized.
iii)The laboratory must be able to provide reliable results with accuracy appropriate to the needs.
iv)The testing laboratory must have the necessary expertise available to be able to assist in the evaluation of the test results and to provide other relevant technical services of an advisory nature. The expertise may be in another organisational unit.
QUALITY CONTROL SYSTEM IN PWD
First-tier QC testing
In first tier QC testing, the Contractor has to carry out the required tests a this own cost during the course of a work. First tier quality control tests are mandatory for all projects including maintenance and repair works, estimated cost of which is above Rs.15 lakhs. As per Govt. circular No.23631/G2/2013/PWD dated 1.11.2013, Contractors shall establish field laboratories at the site of a project, if the estimated project cost is above Rs2 crores. If any test cannot be carried out with the facilities available in the Contractor’s laboratory, it shall be got done in an approved laboratory by the Contractor at his own cost.If the QC test is done in the field laboratory established at site, the test results shall be signed by the Overseer/Assistant Engineer, whoever is supervising the work. It shall also be signed by the Contractor. Copy of test results shall be forwarded by the Assistant Engineer to the Assistant Executive Engineer/Executive Engineer for review. The same procedure shall be followed, in case of tests done in an approved laboratory also.
Second-tierQCtesting
Second-tier QC checks/tests are to be done by the QC wing of PWD on a random basis. However,it is desirable that the QC wing does quality control tests for all major and important items of construction.The frequency of tests shall be as given in this Manual or as specified in the Contract The QC wing is authorized to inspect all projects undertaken by PWD, including maintenance and repair works, irrespective of the estimated cost and conduct quality tests. Results of the tests so done shall also be recorded in the QC module in PRICE software.As far as possible, results shall be forwarded through e-mail to the Executive Engineer with copies to the Assistant Executive Engineer and Assistant Engineer within the minimum time required for carrying out he test.
Third-tier QC checking (Technical audit)
Third party testing
Third party testing is carried out by an independent laboratory other than that of the Contractor or the Department.This is required when the Contractor raise a dispute due to difference in the test results of first-tier and second-tier testing or certain specific tests cannot be carried out with the facilities available in the Contractor’s or Department laboratories or existence of manipulated results are suspected.he Executive Engineer hall decide whether a third part testing is required to settle the dispute. If so, he shall issue a written direction to carry out a test in another approved laboratory.The test shall be arranged to be done in the presence of the Assistant Executive Engineer/Assistant Engineer and the Contractor. The result obtained in this test shall be final and binding on both the Contractor and the Department.The expenses for third party testing shall be met by the Contractor.During sampling for the first-tier and second-tier testing,sufficient number of additional samples shall prepared and kept under safe custody for third-party testing,if warranted.Third-party testing is expected to provide a non biased view and thus a better confidence in the test results.With respect to the methodology of independent testing, the following aspects are importantin order to achieve the right quality:
i)The laboratory must be able to choose and apply the test method that provides a technically correct answer to the problem.
ii)The testing must be performed efficiently, also in such a way that delivery times can be met and costs and charges minimized.
iii)The laboratory must be able to provide reliable results with accuracy appropriate to the needs.
iv)The testing laboratory must have the necessary expertise available to be able to assist in the evaluation of the test results and to provide other relevant technical services of an advisory nature. The expertise may be in another organisational unit.
v)The reports and presentations of the results must be clear and complete, and the recipient must be able to understand and apply them correctly
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