Resident QA/QC Manager
DESCON Engineering
Total years of experience :41 years, 5 Months
Responsible of developing, getting approval from client/consultant and implementing PQP in the line of ISO & project specifications.
Responsible to organize QA/QC team according to volume of each discipline at site.
Installation of fully equipped testing facilities as per specification requirement at site.
Development of QCP/ITP according to project requirement, its implementation of the approved site QC Plan / ITP & monitoring accordingly.
Coordinates with all Independent laboratories like Civil, Mechanical (NDT) and Electrical & Instrumentation for outsource testing as per requirement.
Coordinates with the customers representative on all quality matters
Coordination with project stores for all receipt inspections, IMTE calibration for issuance of monthly status
Verify that the quality related site activities are in accordance with the applicable codes and standards. Ensure that all applicable codes & standards are available at site library.
Actively participates in site meetings to provide QA/QC inputs regarding the Project.
Ensure to issue internal Audits schedule each year and strict implementation is observed.
Actively participates in the external audits of the project.
Coordinate with Client/Consultant on all quality matter
Complete and coordinate the approval of the sites QC technical submitting to the customer
Coordinate with the site construction manager/Site Manager Construction on quality issues
Ensure all quality control documentation is compiled and completed for as-built hand over through the QA Engineer or Document Controller.
Chair Quality meetings with subcontractor for the improvement of quality at site.
Monitoring of Concrete Batching Plant and Asphalt Plant according to the frequency and requirement.
Arrangement of WQT for new arrivals welders and mobilize to site for Initial Production (IP) for further authenticity.
Preparation and approval of WPS (if requires) from third party. Observing RT & UT of the joints of the gates of the Bays in workshop and in field
Coordination with Authorized Inspector(if mandatory) for his visits
Ensure the safety is adhered to at site
Assure all technical documents related to site to project like ITPS, Procedures and drawings are in current status.
Liaises with the Site Manager, Construction, and Project Control Manager of all quality issues during Inspection / testing.
Responsible to manage & submission of final Dossiers.
Being multi diciplined QA/QC Manager, I am responsible of following activities:
Scope of work(04 Units) includes of Civil(Excavation, Concrete(55, 000 Meter Cube/132, 000 of Tons) of Pipe Rack, Equipment & Steel Structure's Foundations, Concrete Pavement in operational Area, Cementitious & Epoxy Grouting, Back-fill and Gravel Fill on Unpaved Areas etc. All the concrete Mix including designs shall be prepared and placed according to ASTM and ACI standard, Mechanical(Installation of Steel Structure and Equipment), About 400, 000 dia inch Pipe fabrication & installation according to American Standard and E&I consisting of laying of cables, terminations and energising of all roots accordingl
The following prerequisites have been prepared, submitted and issued for construction
QC organogram according to Project Scope of Work.
Construction Quality Plan (Project Quality Plan).
Quality Control Plans for General Civil Works, Steel Structure Piping Prefabrication & Erection, Painting Works, Insulation Works, Welding, Heaters & Flares, Pressure Vessels, Heat Exchangers, Rotary Equipment, Static Equipment, Project Management Team Camp. Cathodic Protection (Electrical).
Quality Control Procedures for Calibration of IMTES, Materials Handling, Welding Consumable Control, Welder/ Welding Operator Qualification , High Strength Bolt Tightening, Magnetic Particle Examination & Dye Penetrant Examination, Control of Nonconforming Products, Preventive and Corrective Action, Document and Data Control, Weld Repair, PWHT, Radiographic Examination and continuity Test.
Working in progress for Sour and Non Sour WPS
Sharing inputs in preparing method statements to Execution Team.
To implement DESCON Integrated Management System (DIMS) at the site in line with International Quality Management System ISO 9001:2008,
14001:2004 and 18001:2007.Responsible of providing assistance to the project for receiving inspections and for technical evaluation of subcontractors, vendors and suppliers as per laid down policies/instruction given in Project Quality Plan.To provide assistance to client’s Audit Team and DESCON Corporate Audit Team for surveillance audit of the project .To plan and implement in-house audits Plan to fulfill the requirements of ISO9001:2008(Quality Management System).To attend QA/QC Weekly Meeting, To manage the Quality Documentation according Client system (PCOS) and submission.
To establish QA/QC organogram according to project scope of work.
Development of project specific plan.
To prepare ITPs, WPS, PQR according to project specification for Excavation, Concrete.
To share inputs with execution in preparing method statements.
To implement DESCON Integrated Management System (DIMS) at the site in line with International Quality Management System ISO 9001:2008, 14001:2004 and 18001:2007.
Responsible of providing assistance to the project for receiving inspections and for technical evaluation of subcontractors, vendors and suppliers as per laid down policies/instruction given in Project Quality Plan.
To provide assistance to client’s Audit Team and DESCON Corporate Audit Team in carrying out surveillance audit of the project activities.
To plan and implementation of in-house audits Plan to fulfill the requirements of ISO 9001:2008(Quality Management System), 14001:2004(Environmental Management system) and OHSAS 18001:2007 (Occupational Health Safety Assessment Series).
To attend QA/QC Weekly Meeting, Progress Meeting of the project and reply QA/QC concerns if any.
To coordinate with Third Party for Vetting & Testing.
To develop concrete mix design under supervision of Client and Third Party Testing agency at Third Party Concrete Batching Plant’s premises according to project requirement.
Responsible for maintaining up-to-date Quality Records/Dossiers according to Client System(ICM)
Due to EPC status of Bhikki Power Plant (225 Mega Watts) DESCON placed me in theposition of Resident Manager QA/QC. During my stay I exercised the following responsibilities.
Developing Organogram and hiring of the staff according to the volume of work.
To Prepare and approval of PQP, ITP/QCP for civil, mechanical (Fabrication and erection of structure, Piping installation, Tanks fabrication & installment of Equipment) and Electrical & Instrumentation construction.
To Implementation DIMS (DESCON Integrated Management System
To assist QA part in chalking out site audits plan for a year.
To assist management for the evaluation and selection of suppliers & vendors for civil, mechanical and E& I Materials for construction.
To assist management for the evaluation and selection of subcontractors for Civil Mechanical and E& I Materials for construction.
To install laboratories for testing the materials to be used at site.
To install and arrange calibration of concrete batching plant.
To arrange third part testing agency for calibration of IMTE and mechanical testing (NDT- RT, UT, PT), PQRs.
Development of WPS for materials to be used for piping, structure and Equipment.
Project was in full swing when DESCON shifted me to UAE for new project in July 2009.
Phase -1
Resident Manager QA/QC Mirani Dam Nov.2002 to Aug. 2007 Turbat Pakistan
Contract was EPC and dam was Concrete Faced Rockfilled. Length of Dam 3000 feet with 20 feet
crest in width and125 feet in height. Black top 40 Km Access Road from Airport to Dam, Intake
and outlet structure, 6 feet and 3 feet diameter conduits for connecting intake structure to out let
structure for irrigation net work. Left and Right Bank Canals with major and minors (total length of
irrigation network is 475 Km) and 2650 feet long Aqueduct cum bridge for dual purpose(Traffic and
water conduit).
The following responsibilities have been observing till the completion of project.
• Organogram and assisting HR for hiring of committed staff for field and Laboratory tastings.
• Installation of Laboratories equipped with quality testing of concrete, Rock and soil (all kind of
zone materials with filter materials), Asphalt testing facilities.
• To prepare PQP, ITP/QCP, WPS, PQR and procedures related to the activities carried out at site and got approval from Consultant/Client.
• Investigation of borrow areas with segregation for Dam filling materials.
• Assistance provided to Batching Plants manager in calibration of plants with schedule for further calibration.
• To Prepare Concrete Mix Designs and implementing according to the project requirement.
• To prepare Rolling Compacted Concrete according to the project requirement.
• To monitor all quality testing and field inspection schedule for each activity with Management consultant accordingly.
• To assist and monitor the instrumentation team to install the piezometer during construction of Earthen Core lifts and other earth quake instrument.
• To plan and implementation of in-house audits Plan to fulfill the requirements of ISO 9001:2008(Quality Management System), 14001:2004(Environmental Management system) and OHSAS 18001:2007 (Occupational Health Safety Assessment Series).
• To provide assistance to client’s Audit Team and DESCON Corporate Audit Team in carrying out surveillance audit of the project activities.
• To arrange third part testing agency for calibration of IMTE and mechanical testing (NDT- RT, UT, PT), PQRs and WQT.
• To attend QC meeting with Client/Management Consultant to address the non conformities at site.
• To monitor the quality Dossiers of each element for onward submission to the Client/Management Consultant.
Phase-2
Site Manager MIRANI DAM Sep. 2007 to Sep. 2008 Turbat Pakistan
Being site Manager Mirani Dam liable period I performed the following activities
• To manage the execution of the remaining work according to the project specification.
• To prepare the punch list with Consultants of the project.
• To address punch list for remedial action to close the Nonconformities.
• To hand over irrigation network to client.
• To coordinate the consultants for arranging meeting with Project Director for resolving the technical issues on which consultant disagreed.
• To assist Project Manager for claims and final IPC after completion of liable period.
• To hand over each element of Dam within the specified period
It is fast track project for construction of 22 Km black top roads including small bridges, box & pipe
culverts in Gas Oil Field. Following responsibilities I exercised for the quality construction of the
road.
• Organogram and manpower selection for fast track project
• PQP&ITP was prepared and approved from CLOUGH Engineering Australia.
• To prepare the Internal audit schedule for onward submission to Client
• Installation and approval of Soil, Concrete and Asphalt testing Laboratories
• Erection & calibration of Asphalt Mix batching plant
• Approval of aggregate for Asphalt Mix& Concrete Mix
• Approval of the source of Subgrade, Sub base and Aggregate base course, Cement, Bitumen, Reinforced Pipes were sought from Client.
• Mix Designs for Bituminous Binder and Wearing Course prepared and approved.
• Review Method statements for onward approval from Client.
• To attend QA/QC meeting to discuss on their complaints and job related suggestion to enhance the quality system more effective.
• Monitor the Compaction test of pavement(BBC and BWC)
• To monitor the Final dossiers.
• NSC is a manufacturer as well as a dealer of ELE Equipment for civil construction Testing. It also deals with Environmental and safety Equipment. I was appointed as Quality Assure and Control manager with the following responsibilities. I quitted the job for better career.• I establish a quality policy at corporate and workshop level.• Develop an organogram for QA staff and assist all department to develop an organogram• Establish responsibilities and authorities of the staff for each department.• Inspection of incoming raw materials according to standards (ASTM/AASHTO/BSS/EN).• To develop Method Statements for the construction of each element of Equipment.• To qualify the welders from third party to enhance the quality of welding.• To maintain log of IMTEs each month.• To supervise quality inspection of each product and stamp prior to dispatch to client.• I quitted the company for enhancing the career.
Rehabilitation and resurfacing with carpeting of Roads of Internal City of Lahore, Construction of two ways/ 4-lane 24 Km motorways with single & double barrel culverts and 4-step plaza in old city of Lahore.
Building of Organogram
Preparation of Project Quality Plan, Inspection Test Plan.
To add values in preparing the Method statements for activities.
To prepare Concrete and Asphalt mixes for the project.
To arrange quality testings for materials to be used for Subgrade, Base course, Aggregate base course, Concrete, Binder and wearing course, Prime Coat and Tack Coat.
To install site laboratories for materials testing.
• To issue the monthly Audit schedule for in house Audit and increase the frequency of Audit to track the activities in the line of ISO Clause.
• To assist site management for approving the vendors, suppliers, subcontractors for site activities.
• To arrange calibration of Concrete Batching and Asphalt Mix batching plant for trial mixes of concrete and Bituminous mixes.
• To establish a Library of standards like ASTM, AASHTO, DIN, BSS, EN for the reference for construction.
• To assist external Auditor to achieve the Accreditation to ISO Certification for the company and Company (HRL) received the accreditation to ISO 9000 successfully and appointed me to look after the running projects with reference to the implementation of ISO system and I added my values wherever these were required.
HRL was thriving at that time and seeking a person who could assist to implement QA system for accreditation to ISO 9000 Certification. Certainly it was requirement of the era as well company had gauged the pressure from the clients (Maurobini/JGC) which had been required to dilute. I joined
HRL in October 1998 when company was dealing with multi disciplines at Pak Arab Refinery at Qasba Gujarat Pakistan and multi disciplines were included of Civil, Mechanical, E&I and
HVACS. Anyhow I accepted the challenge and stepped forward for the goal.
A winning organogram and hiring of committed staff
Established Quality policy at site and assist discipline heads to establish responsibilities and authorities for themselves and their staff.
To establish Testing Laboratories and published the manual.
Arrange calibration of the Equipment and maintain IMTEs list each month.
To develop PQP, ITP, WPS, PQR, ITS (integrated tracking system of pipes) and WQT for welders.
To issue the monthly Audit schedule for in house Audit and increase the frequency of Audit to track the activities in the line of ISO Clause.
To assist site management for approving the vendors, suppliers, subcontractors for site activities.
To arrange calibration of Concrete Batching and Asphalt Mix batching plant for trial mixes of concrete and Bituminous mixes.
To establish a Library of standards like ASTM, AASHTO, DIN, BSS, EN for the reference for construction.
To get approval of Raw materials to be used in construction.
To conduct series of trials to arrive on suitable Concrete Mix for the Structures, Buildings and Racks as per project specification.To conduct trials for BBC and BWC for road mixes.
To assist external Auditor to achieve the Accreditation to ISO Certification for the company and Company (HRL) received the accreditation to ISO 9000 successfully and appointed me to look after the running projects with reference to the implementation of ISO system and I added my values wherever these were required.
It was the time when company was preparing for the Accreditation to the ISO certification. I was selected a member of core team who was working for the certification under the supervision of Head QA/QC Corporate. My role was to inspect the incoming(procured) materialsI was observing the following
• Somehow it was cumbersome position to deal with the vendors, suppliers and manufacturers according to the different specification of the different projects but I overcame the situation and developed a team for inspection of the incoming materials and my team succeeded to reduce the rate of rejection of materials to zero caused to speed up the pace of work and project receives excellent impact in shape of cash flow.
• It was my additional duty to take care of calibration of IMTEs using at site.
• I added my values in developing the standard Method Statements for the activities at site.
Being I/C QC Chakwal Cement, I performed the following responsibilities:
• Set up a civil laboratory for quality testing of Raw materials and concrete testing, soil testing at lab and field.
• Adjustment of the crusher production according to Project specification(ASTM, AASHTO, BSS)
• Corner library for standards and reference notes
• Supervision of Cement, Aggregate, sand, Soil testing in Laboratory
• Calibration of Concrete Batching Plant
• Preparation of concrete Mix designs of different classes according to the requirement of the project.
180 Km long roads included all structures (Bridges, Culverts, Drainage along the roads, parking areas, spin on and spin off. sub-grade, sub base, aggregate base course, Prime coat and Tack Coat, level course, binder course and wearing course, concrete (Class A, B and C), Masonry work, Road Marking and Road Signs etc.
Being Senior Materials Engineer I was responsible of the followings for 180 KM, 2 ways Road:
• Recruit the lab and field testing staff according to volume of work
• Investigation of borrow areas for subgrade, source for crush materials for Concrete, Sub base, Aggregate Base Course, Sand for Concrete, Bitumen for Mix, Prime and Tack Coat materials for Road, paints, Sign Boards.
• To assist sub contracting department for the selection of subcontractors, suppliers and vendors.
• Preparing the Concrete mix designs for blinding and quality concrete for Culverts, bridges& curbstones
• Preparing and implementing mix designs for binder and wearing courses.
• Monitoring the calibration of Asphalt Mix plant and Concrete Mix plant according to the schedule.
• Installation of Materials Testing Laboratories in all three sections for joint testing.
• Supervision of Laboratory and Field testing to project specification and ASTM.AASHTO and BS standards.
• Ensure materials supply in time.
• Attend meetings with Client and company management for addressing day to day problems.
• Maintain quality records for onward submission to client/consultant for interim payment certificate.
Camel over Pass, Culverts, Bridges, Flyovers, Rest areas (with Benzene Stations, Mosques & Restaurants) New Jersey barriers, Precast Units, Rip Raps, Stone pitching, Marking and Sign Boards, Railing Pedestals for lighting poles etc: Concrete 100, 000 M3, Subgrade: 60, 000M3: Sbbase: 39000 M3, Aggregate Base Course: 50, 000M3 Prime and Tack Coat: 1800M3, Bituminous Base Course: 180, 000M2, Bituminous Wearing Course: 180, 000 M2, Rip Raps: 20, 000 M2, Stone Pitching: 30, 000M2
Being Senior Materials Inspector (Field & Lab. Quality Controller), I was responsible of the followings for the 100 km long Halban section at Riyadh-Taif Road with flyovers, bridges, and culverts & camel over pass etc:
• Supervision of lab and field testing according to the specification
• Supervision of Mix Designs of concrete and asphalt
• Supervision of pre-stressing activities for the bridges and flyovers
• Supervision of Batching plants during production
• Monitoring the calibration of Lab Equipment, Operators and Batching Plant.
• Checking and arranging quality dossiers for onward submission to client
Terminal Building connected with Two Satellites, Utility Tunnel, Grid Station, Apron, Elevated water Tank (by Slip form methodology), Parking Area, Mosque, Departure Level Bridge, Precast Units includes of Architectural Units (To expose yellow aggregate by sand blasting), Pedestal for lighting pole, Instrumentation and erection, Internal (Roads with black top), Ramp maintenance facilities for airlines Vehicles
Management assigned me as QA/QC coordinator for the project in between Contractor and Field Engineering. I performed the following duties:
• Arrange QA/QC meeting among Field Engineering Consultants (NESPAK), Contractor (SOGEA) and MC (BECHTEL) to resolve QC matters for enhancing the space of work.
• To review Non conformities and follow ups.
• Arrange and supervise Third party testing of the materials like Steel, RCC Pipes and Bolts.
• Reporting the production of precast units (all kind) to Manager QA/QC.
• Reporting the receiving quantity of aggregates to be used for concrete, asphalt mix and cement treated base to QA/QC Manager.
•To review final dossiers for final submission to client.
11800*150 Feet long Concrete Runway with 25 feet wide flexible shoulders either side with 150 feet fair weather strip either side, Dumbbells to connect with old runway, Flexible High and Medium Speed Taxiways, DVOR Building, Installation of Conduits for lighting in the centre line and for accessing the taxiways to Apron and vice versa, New apron facility for 747 Boeings
My first phase with BECHTEL starts from June 1986 to January 1989 at Lahore Airport as QC Inspector and instructor for transfer of technology to Government Airport Construction Agency’s Engineers. Following responsibilities I performed during my stay at Lahore New Runway Project. I was assigned on Earthwork and Asphalt pavement section with additional duty of Trainer for transfer of technology.
• Installation of Earthwork and Asphalt Laboratory at sit
organogram and recruiting of staff for lab and field both.
To prepare ITP for measuring the quality level of the activities at site
• Calibration of Asphalt mix Plant at site.
• Approval of source and in stage quality testing of the materials for construction.
• Supervision of asphalt Mix designs in contractor’s Lab. for Bituminous Base and Wearing Course.
• Supervision of Quality testing of materials at Laboratory and in the field.
• To attend meetings with Project Director for monitoring the day to day progress and to address the site complaints.
• Chalk out a syllabus for the trainee Engineers of Airport development agencies and arrange lectures and practical training at site and in laboratory.
• Arrange quick tests for the trainees.
• Preparation of final dossiers
To manage Concrete Batching Plant, Crusher Plant and Asphalt Mix Plant was in my duty. The following responsibilities were in my scope of leadership.
• Management of Central Laboratory (Makkah Region)
• Supervision of testing in CMTL (Central Materials Testing Laboratory) and reports preparation for related consultants.
• Quality control supervision of materials produced at Crushing plant according to the requirement of project specification
• Supervision of the production with reference to quality of Concrete Batching Plant and Asphalt Plant and prepare a log for the same for traceability.
• Monitor the calibration of concrete batching and asphalt mix plant according to specified interval by the third party.
• Monitor the maintenance of Crusher plant, Concrete Batch Plant and asphalt Batching Plant according to monthly table given by Mechanical department
• Conduct quality control audits of technicians working for the project in Makkah region.
• Conduct quality control audits of equipment under use in Laboratory and establish a report according to ASTM.AASHTO Standard.
• Maintain and establish IMTEs list each month.
• To establish Concrete and Asphalt Design according to Projects requirements and maintain the supply of mixes according to schedule of each project.To monitor precast yard with respect to all ongoing activities and have close interaction with clients for addressing time to time complaints.
•Install and maintain site Laboratories at each project site and place the staff accordingly. Selection and seek approval for Quarries/Borrow Areas for Embankment Materials subgrade, sub base, Sand for Concrete and Aggregate Base Course. Selection and Seek approval for Cement and admixtures to be used for concrete.Supervision of final dossiers for each project. Attend meeting with management to discuss the shortcomings, bottlenecks and future plans for the coming materials. Attend hand over activities with Construction and project Managers
•I was responsible of quality testing carried out in CMTL with maintaining the log to present the reports Materials Engineer for further discussion with management/client.
•Review all final dossiers of the various projects for dispatching to related Ministry/departments
•Assist handing over team in Laboratory testing
I was assigned to conduct the testing on the samples from different projects for checking the materials and reporting to Section Head for evolution, assessment and recommendation
In the capacity of Materials Testing Inspector, following were my responsibilities:
• It was my duty for sampling; supervise testing and preparing reports for Materials Engineer for his evaluation and recommendation.
• I was also assigned to visit Crusher Sites for QC testing and adjustment of Crushers.
• To evaluate the Asphalt Mix design and report to Laboratory Manager for further evaluation and adjustment.
• To carry out the concrete mix design according to specification and report the results to Lab. Manager for his perusal and implementation
• To prepare and maintain logs of testing and materials for reference
• I was assigned at Crusher for testing the quality testing of crushers and prepare report for Crusher General Forman for his assessment and adjustment.
• Prepare daily log of the production of the crushers for site manager
I studied Astor- Physics with analysing the Spherical Geometry with calclus, General Mathematics I studied Calclus and Analytical Geometry,Mecanics(Statics,Kinematics) Set Topology, Scalers and vectorsand Mathematical Methods and Statistics(all three Majors) And English as literature.