QCP r1 not approved

EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT SHIMIZU CORPORATION MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN QCP-01 SHIMIZU CORPORATION PACKAGE D CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT GUIDANCE NOTES Where this page is over-stamped with the words “Controlled Copy” this means: a) Distribution is centralized - in this case of this document from the Quality Control Manager; b) Each copy is issued to a particular person or organization If the document is no longer required it should be returned to the relevant person; c) It is not to be photocopied either in whole or in part Additional copies are available on request; d) Copy holders will be automatically issued with any amendments Responsibility for incorporating such amendments rests with the copy holder 15 / 11/ 06 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT SHIMIZU CORPORATION REV NO ISSUE DATE MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN PREPARED BY QUALITY CONTROL STAFF REVIEWED BY QUALITY CONTROL MANAGER REVIEWED BY SITE MANAGER APPROVED BY ACTING PROJECT MANAGER B.N THUAN L DE OCAMPO Y UCHIDA Y UCHIDA OTHERS (AS APPROPRIAT E) EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN SHIMIZU CORPORATION TABLE OF CONTENTS FOREWORD PART - MANAGEMENT SYSTEM OVERALL OBJECTIVE 1.1 PHILOSOPHY AND OBJECTIVE 1.2 VALUES 1.3 POLICY 1.4 AIMS 1.5 SCOPE AND APPLICATION ORGANISATION 2.1 ORGANISATION CHART 2.2 ORGANISATION NARRATIVE RESPONSIBILITIES 3.1 PROJECT PERSONNEL 3.2 MANAGEMENT REPRESENTATIVE 3.3 VERIFICATION PERSONNEL 10 3.4 DELEGATION IN ABSENCE 10 3.5 KEY RESPONSIBILITIES 10 AUTHORITY MATRIX COMPARISON PLANNING WITH AND 14 ISO 9001 19 REVIEW 24 COMPLAINTS 24 SYSTEM 25 IMPROVEMENTS 26 PART - QUALITY CONTROL PLAN PROCEDURES INTERNAL PROCEDURES MATRIX AND DOCUMENTATION 27 28 Page of 53 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN SHIMIZU CORPORATION TABLE OF CONTENTS (CONT’D) INTERNAL PROCEDURES MATRIX 38 2.1 INTRODUCTION 38 2.2 SUMMARY OF PROVISIONS 39 2.3 GOVERNMENT DECREE NO 209/2004/ND-CP 41 2.4 FLOWCHART 49 PROCEDURES DEFINITIONS AND 50 REFERENCES 51 4.1 DEFINITIONS 51 4.2 REFERENCES 51 REVISION RECORD 51 APPENDICES: ORGANISATION CHART FLOWCHART TRANSLATED COPY OF DECREE NO 209/2004/ND-CP TRANSLATED COPY OF DECREE NO 209/2004/ND-CP INSPECTION FORMS DAILY SITE USED FORMS MONTHLY SITE USED FORMS FORMS USED FORMS SUBMITTED PRELIMINARY INSPECTION FOR AT DECREE NO 209/2004/ND-CP CONSTRUCTION WORK COMPLETION STAGE AS PART OF MONTHLY REPORT AND TEST PLAN FOR MAJOR ELEMENTS OF THE AND TEST PLAN FOR OTHER ELEMENTS OF THE WORKS 10 PRELIMINARY INSPECTION WORKS Page of 53 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT SHIMIZU CORPORATION MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN Page of 53 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT SHIMIZU CORPORATION MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN Foreword Shimizu Corporation is heavily involved in the Construction industry, specifically contracting in the following construction sectors: DESIGN, MANAGEMENT BUILDING WORKS; AND CONSTRUCTION CIVIL ENGINEERING OF AND The range of projects and clients range from domestic to international In this particular case, the relevant project is described below: PACKAGE - D CONVEYANCE SEWER CONSTRUCTION EXISTING COMBINED SEWER IMPROVEMENT SECONDARY INTERCEPTOR SEWER CONSTRUCTION The location of the Project is: HO CHI MINH CITY - PEOPLE’S SOCIALIST REPUBLIC OF VIETNAM The Employer is: • • GOVERNMENT OF THE SOCIALIST REPUBLIC OF VIETNAM PEOPLE’S COMMITTEE OF HO CHI MINH CITY EAST-WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY; The Engineer is: • PACIFIC CONSULTANTS INTERNATIONAL (PCI) IN ASSOCIATION WITH VIETNAM WATER, SANITATION, AND ENVIRONMENT CORPORATION (VIWASE) AND WATER AND SANITATION ENGINEERING CONSULTANT (WASE) Notwithstanding the abovementioned, it should be further noted that other Civil Engineering Construction and Design works would be carried out in the region These, not in any particular order, include, but are not limited to the following:      HIGHWAY CONSTRUCTION BRIDGE CONSTRUCTION TUNNEL CONSTRUCTION GENERAL INFRASTRUCTURE CONSTRUCTION GENERAL SUPERSTRUCTURE CONSTRUCTION Page of 53 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT SHIMIZU CORPORATION MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN In the event of such undertaking of any of these Projects this document and the general principal of the application shall be implemented with the necessary revisions, where and if necessary, required The document is divided into two parts: Part Part MANAGEMENT SYSTEM QUALITY CONTROL PLAN (PROCEDURES AND DOCUMENTATION) Part of this document describes how the Management System is organized, defined and structured to ensure that the Project is operated and delivered in accordance with this document Part of this document describes the practical implementation of the Management System through the Quality Control Plan It describes the appropriate procedure(s) and the necessary documentation In addition to the Conditions of Contract that require compliance with ISO 9001, the Quality Control Plan shall comply with requirements of the Government Decree No 209/2004/ND-CP (on Quality Management of Construction Works) By virtue of this document, Shimizu Corporation shall ensure the generic application of the provisions contained herein to ensure an efficient, effective Management System and Quality Control Plan that shall deliver a quality product to meet the Employer’s requirements Page of 53 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT SHIMIZU CORPORATION MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN PART MANAGEMENT SYSTEM Page of 53 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT SHIMIZU CORPORATION MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN OVERALL OBJECTIVE 1.1 Philosophy and Objective “To Meet the Requirement of the Employer and Society” To the uninitiated, the term “Quality Assurance”, “Quality Control”, “Test” and “Inspection” are often misunderstood Some contractors and craftsmen feel that these terms are directly related to wasted time and money Some believe that the sole intent of the Contractor’s Quality Control Organisation is to find something is incorrect in order to justify their existence This is far from the truth With an effective Management System and Quality Control Plan, rejections are minimized and as a result cost and time is saved The Employer’s acceptance is facilitated and assured to his requirements Defects and subsequent necessary remedies thereof are minimized This document is prepared to enable all the personnel of the Main Contractor to understand and be aware of their own duties to ensure that the works are accomplished in strict compliance with the requirements of the Contract, the requirements of ISO 9001 and the Government Decree No 209 where applicable The primary purpose of this document is to guarantee that the quality of materials and workmanship is continuously evaluated; to ensure that the finished product shall conform to the project specification and Contract drawings It shall include pre-construction and inprogress checking, testing and documentation as well as inspection of the work being performed on Site This document has been prepared in accordance with the ISO 9001: Quality Management Requirements, the Government Decree No 209 on Quality Management of Construction Works in addition to the Main Contractor’s own Quality Policies and objectives The application of this document shall be in accordance with the requirements of the Contract 1.2 Values Individual Skills The Main Contractor will create opportunities for individual action at all levels of the project using the Main Contractor’s combined talents to ensure the projects’ overall success Teamwork In order to develop mutual recognition and trust with all concerned the Main Contractor’s Management System and Quality Control Plan Page of 53 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN SHIMIZU CORPORATION will promote willingness to assume responsibility for specific tasks and the project at large Communication The Main Contractor’s principle is to create and encourage an open dialogue policy that will provide information flow Open communication will promote responsible decision making among employees Performance A periodic review of the Main Contractor’s performance against these principles will be carried out 1.3 Policy “To Meet the Requirement of the Employer and Society” It is the policy of Shimizu Corporation to provide the Employer with products and services which: • Satisfy the requirements of the Contract Specification; • Are available at the required time; • Are economical; • Are reliable; The policy is achieved by a commitment to quality based on the following: • Defining quality so that everyone has the same understanding of what is to be achieved and why quality is essential to the success of the Project; • Developing the approach of recognising and preventing a problem before it occurs; • Enforcing the policy that each person is responsible for the quality of his or her own work; • Implementing quality control and assurance throughout the project by a written system of working procedures; The Main Contractor’s Quality Control Procedures are implemented to enforce a Quality Policy that is conducive to the requirements of the Contract and are based on the following principles: • Site procedures that ensure all operations are planned to meet the Employers requirements; • Formulating systems that identify requirements and that ensures an uninterrupted, accurate, updated flow of information, thus eliminating source of errors; • The Main Contractor’s Managers and supervisory staff are responsible for issuing instructions and delegating work They Page of 53 EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN SHIMIZU CORPORATION TOTAL Page 11 of 10 Appendix No EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT SHIMIZU CORPORATION MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN APPENDIX NO PRELIMINARY INSPECTION AND TEST PLAN FOR MAJOR ELEMENTS OF THE WORKS Appendix No EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN SHIMIZU CORPORATION CONCRETE INSPECTION Supplier Factory and Origin Reinforcemen t Re-bar material AND TEST PLAN GENERAL PROCEDURE On-Site (Construction Site) Construction Drawing Page of 10 Specification Appendix No Shimizu Corporation Internal Inspection The Employer / Engineer Pre- Testing Facility Transport (Symbol Mark System) SHIMIZU CORPORATION Item Method Statement Working Drawing Shop Drawing OF HO CHI MINH CITY EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT Concrete HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT Work PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT Inspection of Testing Facility OnSite Inspec tion Purpose of Inspection Test Material Each Structure Component MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN Test Method Requiremen t Re-bar bending REINFORCEMENT MaterialFormworkDuring Construction Approval Fabrication Test Test No No Place Place Re-Bar Fabrication Material Test for tensile strength JIS Z 2241 JIS G 3112 Concrete (Batching Plant - Off Site) Construction Reinforcemen Test for compliance with Material for t bending and the drawings concrete approval fabrication CONCRETE Testing Facility Visual and measurement Testing Facility Construction dwg and approved working dwg Before concreting Curing Transport Test Tag for compressive (Cement: Concrete Trial Sealing Mix design System) strength Material Cement Admixtures Off-Site Laboratory casting inspection Trial Mix Mix sample / every arrival Concrete at Site Supplier and Trial Mix Test for slump loss Test for workability Test for basic physical properties Test for basic Testing physical properties Facility ASTM C39-94 Spec 4.2.1.3 Arrival AASHTO T119 Spec 4.2.1.3 Visual inspection TCVN 6016, 6017, 4030 ASTM C494 Mixing TCVN 62601997 ASTM C494 Page of 10 20 [TBC] [TBC] 1 Supplier Supplier Removal of Supplier Formwork Supplier [TBC] Structure Each batch Supplier component used completion inspection Position Shimi Re-bar d check Re-bar s Concret etc Check p concr Concret for co test Slump t Tempera Check c condit Check t remov formw [TBC] Supplier Cert Appendix No Dimens struct EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN SHIMIZU CORPORATION Item Water Fine aggregate Coarse aggregate Purpose of Inspection Test Test Method Test for cleanliness / purity TCXDVN 302-04 TCVN 6492-99 TCVN 6194-96 TCVN 6200-96 TCVN 4560-88 TCVN 2671-78 Clay lumps and friable material Sieve analysis Test for fines Test for inorganic impurities Quantity Clay lumps and friable AASHTO T112-91 JIS A1102 equivalent JIS A1103 equivalent JIS A1105 equivalent AASHTO T112-91 material Sieve analysis Test for fines Quantity JIS A1102 equivalent JIS A1103 equivalent Requiremen t TCXDVN 30204 Spec Spec Spec Spec Material Approval Test No Place Supplier 4.2.2.5 4.2.2.5 4.2.2.5 4.2.2.5 1 1 Supplier Supplier Supplier Supplier Spec 4.2.2.6 Spec 4.2.2.6 Spec 4.2.2.6 1 Supplier Supplier Supplier During Construction No [TBC] Each batch used Each batch used Each batch used Each batch used Each batch used Test Place [TBC] Supplier Supplier Supplier Supplier Supplier Supplier Supplier Construction Formwork fabrication Survey, visual inspection Rebar fabrication Measurement Page of 10 Each component of structure Each component of structure Appendix No EAST - WEST HIGHWAY AND WATER ENVIRONMENT PROJECT MANAGEMENT UNIT OF HO CHI MINH CITY HO CHI MINH CITY WATER ENVIRONMENT IMPROVEMENT PROJECT PACKAGE D - CONVEYANCE SEWER CONSTRUCTION AND EXISTING COMBINED SEWER IMPROVEMENT MANAGEMENT SYSTEM AND QUALITY CONTROL PLAN SHIMIZU CORPORATION Item Concrete casting Purpose of Inspection Test Check rebar, formwork installation Test for slump loss Test for compressive strength (sampling) Curing Completion Test Method Requiremen t Joint measurement & visual inspection AASHTO T119 Spec 4.2.1.4 Spec 4.2.1.4 ASTM C39-94 Visual inspection Dimension Test for compressive strength Joint measurement & visual inspection ASTM C39-94 Spec 4.2.1.4 Page of 10 Material Approval Test No Place During Construction No Each component of structure 20m3