CONTEMPORARY STRUCTURE CO.

FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

TABLE OF CONTENTS
Item # Description Page #
Section 1: Project Quality Policy 3
1.1 Statement of Authority 3
Section 2: Introduction 4
2.1 Amendments and Re-issue 4
2.2 Quality Objectives 5
2.3 Terms and Definitions 5
Section 3: Management Responsibility 7
3.1 Quality Policy 7
3.2 Organization 7
3.3 Responsibility and Authority 8
3.4 Personnel and Resources 9
3.5 Management Review 9
Section 4: Quality System Outline 10
4.1 Quality System 10
4.2 Quality System Procedures 11
4.3 Quality System Documents 12
4.4 Contact Review 12
4.5 Document and Data Control 13
4.6 Purchasing 14
Control of Client Supplied and Contractor Supplied
4.7 16
Materials
4.8 Product Identification and Trace-ability 16
4.9 Special Process Control 17
4.10 Inspection and Testing 18
4.11 Inspection and Test Records 19
4.12 Inspection and Test Status 20
4.13 Control of Nonconforming Product 20

Page 1 of 34
 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

TABLE OF CONTENTS
Item # Description Page #
4.14 Corrective and Preventive Action 21
Control of Measuring, Test and Inspection
4.15 23
Equipment
Handling, Storage, Packaging, Preservation and
4.16 24
Delivery
4.17 Control of Materials and Storage Guidelines 25
4.18 Internal Quality Audits 26
4.19 Audit Planning and Execution 27
4.20 Training 27
4.21 Statistical Techniques 28
4.22 Servicing 29
4.23 QA / QC Reports 29
4.24 Quality Management Report 30
4.25 Inspection Notification 31
4.26 Control of QA / QC Documents 31
4.27 Pre-commissioning Phase Quality Control Activities 32
4.28 Technical Queries 33
4.29 Waivers 33
4.30 Geo-technical / Soil Investigation 33
Compliance to the Client Standards and
4.31 33
Specification

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

SECTION 1: PROJECT QUALITY POLICY

1.1 STATEMENT OF AUTHORITY

It is the Policy of Contemporary Structure Company (COST) to serve a

dependable level of work performance that meets the Client quality
standards and international standards whichever is more stringent.

To achieve this goal the objective measure of these systems and processes
to provide a seamless organization during the prosecution of contracts /
projects undertaken by COST

Quality in all matters of construction, fabrication and materials control, is

herein defined as meeting the requirements and specifications as a
mandatory within the Quality Control Program

The Quality Control Program Document is covering the Quality requirements

of Saudi Aramco, and COST construction personnel shall follow without any
deviation.

COST laid down as a basic principle that, the Project construction activities
shall be conducted in accordance with the requirements of the Project
Quality Control Program and will be audited by the COST QA
Manager/management at various stages of the completion as defined in the
project quality assurance program.

____________________
Managing Director (COST)

Date: _______________

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

SECTION 2: INTRODUCTION

COST Company has been engaged in the construction industry related to

housing, commercial and industrial facilities.
The success of the company has been ascribed to good governance, excellent
management and stringent function of an effective Quality Plan based on Client
satisfaction. It is the main goal of the company to satisfy the requirements of the
client by strictly adhering to quality requirements as predetermined in the
contract.

This quality Plan is set forth to illustrate and specify clearly the general quality
policies, procedures, and practices required for the construction of the
contracts / projects undertaken by the Company.

This Quality Plan was visualized and prepared on the basis of the requirement of
the contract document. It serves as a reference and in line with any other
standards as may be required as a part of the client requirements and COST
Company’s internal QUALITY MANAGEMENT SYSTEM.

It is an efficient management tool in maintaining the employee’s awareness of

their responsibilities with the company’s quality objectives.

This Quality Plan and the work procedures outlined herein describe the COST
company Management System and is thought-out to make sure that quality
necessities are recognized and properly maintained.

2.1 Amendments and Re-issue

The Quality Assurance Department shall periodically review and assess the
Quality Plan with the other departments to re-affirm its sufficiency,
effectiveness and compliance to Client’s quality requirements. The minimum
occurrence for review of the Quality Plan is once every six (6) months.

Amendments to the Quality Plan are made as required to reflect the client
requirements. Amendments are made by replacement of the affected
area(s) and are identified by modification reference and date. Amendments
are numbered one after the other until all the changes are incorporated..

Whenever the Quality Plan is revised, affected sections are superseded with
revised one and shall be removed and destroyed.

The Quality Plan amendment record indicates all the amendments in the
latest issue of the Quality Plan.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

A complete list of Quality Plan holders is retained and any amendments and
re-issue are automatically distributed to all concerned parties.

2.2 Quality Objectives

The objectives of the Quality Plan are;

 To ensure that approved methods and procedures are utilized for each
specific work phase of a project.
 To minimize rework during the construction period.
 To ensure that safety of personnel, the facilities and environment had
been carefully considered and adhered to.
 To comply with international and Client codes and standards.
 To demonstrate the fulfillment of the contract requirements as stipulated
in contract documents.
 To ensure that, quality requirements are determined and satisfied
throughout all phase of the work (procurement, construction and pre-
commissioning phases).
 To ensure that approved procedures, inspection and test plans,
management review and audit program are in place and utilized
throughout all work phases.
 To provide means for early and prompt detection of deficiencies and its
timely and effective corrective action.

2.3 TERMS AND DEFINITIONS

Contractor: supplier in a contractual obligation

Customer: recipient of a product or services provided by the supplier

Certification: the authoritative act of documenting compliance with

requirements

Documentation: any recorded or pictorial information describing, defining

procedures or results

Defect: non-fulfillment of an intended usage requirement, or reasonable

expectation including one concerned with safety

Hold point: work will be held until the inspection or test has been
satisfactorily completed.

Inspection: an activity such as measuring, examining, testing or gauging

one or more characteristics of an entity and comparing the results with

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

specified requirements in order to establish whether conformity is achieved

for such characteristic.

Non-conformity: non-fulfillment of a specified requirement

Product: result of activities or processes

Quality: the totality of characteristic of an entity that bear on its ability to

satisfy stated and implied needs

Quality Assurance: all the planned and systematic activities implemented

within a quality system to provide adequate confidence that an entity will
fulfill requirements for quality

Quality Audit: a systematic and independent examination to determine

whether quality activities and related results complied with planned
arrangements and whether these arrangements are implemented effectively
and are suitable to achieve objectives

Quality Control: an operational techniques and activities that are used so

that its operations and services conform to the quality requirements as laid
down in the contract documents.

Quality Manual: a document stating the quality policy and describing the
quality system of an organization

Quality Plan: a document setting out the specific quality practices

resources and sequence of activities relevant to a particular service,
contract or product

Quality Policy: the overall intentions and direction of an organization with

regard to quality as formally expressed by top management

Review: an independent assessment undertaken by an individual or group

of the area under review

Rework: action taken on a non-conforming product so that it will fulfill the

original requirement

Specification: the document that prescribe in detail the requirements with

which the product or service has to comply

Standard: a document approved by a generally recognized body which

results from the process of formulating and applying rules for an orderly
approach to a specific activity

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

Service: the results generated by activities at the interface between the

supplier and the customer and by the supplier internal activities to meet
customer needs

Subcontractor: an organization that provides a product to the supplier and

it may be called sub-supplier

Supplier: any individual or organization that furnishes items or services to

the customer

Test: the determination or verification of the capability of an item to meet an

specified requirements by subjecting the item to a set of physical, chemical,
environment or operating conditions

Witness Point: the inspection will be witnessed by inspection QC staff

SECTION 3: MANAGEMENT RESPONSIBILITY

3.1 Quality Policy

Management’s proclamation regarding quality policy is given in the section

1.

3.2 Organization

3.2.1 The organizational chart covers the positions of all performers

who manage and verify work affecting quality. That work
includes the following activities as minimum:

 Preventive action against non-conformities for the materials,

the processes and the quality system.
 Detection of any problems in the materials, the processes and
the quality system.
 Problem solving participation
 Verification of corrective actions
 Vigilant on non-conforming products

The detailed responsibilities and authorities per job title are

addressed within the Quality Procedures under
“Responsibilities”.

3.2.2 Resources:

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

COST has provided adequate resources of equipment, devices

and tools and established qualifications, for management and
performance of work affecting quality and for verification activities
including internal quality audits.

COST also identified and implemented training needs time to

time at an equal intervals.

3.2.3 COST QA manager ensure the implementation and maintenance

of the quality system in accordance with Client requirements and
internal standards and requirements...

COST QA Manager compile reports on the performance of the

quality system to be used as a basis for improvement by the
Management.

3.3 Responsibility and Authority

3.3.1 The Project Manager has the overall authority and responsibility
for executing the project successfully in time. His duties and
responsibilities includes but not limited to the following;
 Representation to the Client for all matters related to the
contract.
 Overall management of the project activities and control of
related personnel.
 Coordinate with client and Head office with foreseen look
ahead plan to complete the task in a right time and in a
right manner.
 Implementation of any step required to prevent delays,
budget overrun and conditions adverse to quality
objectives.

3.3.2 The QA/QC Manager directs all activities of the project quality
organization, reporting directly to the project manager but,
maintaining an operational link with the Client. His duties and
responsibilities are as follows;
 He is the authorized company quality control representative
to the Client.
 He is responsible for all matters pertaining to the quality
control plan.
 He is responsible in ensuring that all Client requirements
are strictly adhered to.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

3.3.3 The Site QA/QC Supervisor is responsible for the direct

supervision of the relevant discipline QA/QC inspectors and
reports directly to the QA/QC Manager. He is responsible for
clearing the daily inputs to the Project Inspection Log Book. He is
responsible for ensuring that the discipline inspectors have
access to necessary standards, specifications and latest
construction drawings. He shall review activity inspection reports
to ensure these are concise and complete.

3.3.4 The QA/QC discipline inspectors reports administratively to the

QA/QC supervisor for their daily inspection activities. They are
responsible for the implementation of the Inspection and Test
Plans. They are responsible in originating non-conformance
reports and have the authority to stop any work not complying
with the specifications, approved construction drawings and
quality plan requirements.

3.3.5 The third party inspection and testing agencies approved by the
Client shall be responsible for carrying out all test and inspections
requiring third party inspection and testing, ie, soil compaction
test, concrete sampling, compressive strength tests, NDT/NDE,
test equipment and measuring instruments calibration, instrument
calibration and others.

3.4 Personnel and Resources

3.4.1 All QA/QC personnel including subcontractors and third party

inspection agencies shall be subject for approval by the Client
prior to the start of work for each individual.

3.4.2 A listing of QA/QC personnel sorted by discipline shall be

submitted to the Client thirty days from the effective date of the
contract and updated monthly with all the changes noted.

3.4.3 For any changes in the QA/QC personnel due to vacations,

illness, temporary assignments, emergency leave, resignations
and other reasons, the Client representative shall be advised of
such QA/QC personnel changes at least thirty (30) days in
advance and as soon as possible for other reasons.

Page 9 of 34
 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

3.5 Management review

3.5.1 The company Quality Steering team will conduct reviews chaired
by a member of Senior Management and /or a copy of minutes of
meeting shall be submitted for management review and action if
any as may be required. This management review meeting of the
Quality System shall be conducted every six (6) month in general

Review objectives:
 Ensure the efficiency and appropriateness of the Quality
System.
 Monitoring and evaluating the trends of nonconformity's within
the system.

3.5.2 The management review of this project will be planned by QA

manager based on project requirement and will involve Client as
may be needed. The schedule will be advised well before the
scheduled review.

Section 4: Quality System Outline

4.1 Quality System

4.1.1 The quality system employed in the project has been structured
in accordance with the requirements of the contract. The Quality
System was designed primarily to satisfy the managerial
requirements of COST Company and the Client.

4.1.2 The quality management system is described in this Quality Plan

and includes organizational structure showing key job titles, job
descriptions and details of how the levels are tiered.

4.1.3 The Quality Plan shall be submitted to the as required by the

contract documents.

4.1.4 The Quality System described in the Quality Plan shows that
COST Company has a planned and systematic approach in

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

obtaining and maintaining the quality objectives in the job. It

shows that personnel have the necessary training to perform
their work and definitions for quality and quality related activities
are reflected in the documented system and represent COST
Company interpretation to suit its own objectives.

4.1.5 Details of who, what, how and when are properly defined in the
Quality plan and other referenced COST Company documents.

4.1.6 Project inspections, witnessing, monitoring and signature shall be

in accordance with the approved Inspection and Test Plans.

4.1.7 The inspection and testing requirements shall be carried in

accordance with the work procedures referred to as Standard
Operating Procedures (SOP) in this manual and approved
Inspection and Test Plans.

4.1.8 The request for inspection (RFI) procedure details the

responsibilities for the following;

 Initiation of the RFI

 Acceptance of the works

 Closing out of actual inspection

4.1.9 Master index and Revision control log shall be maintained to

update the revisions, as per Section 2.1 of this Quality Plan
Manual.

4.1.10 A two week look ahead inspection schedule for all inspection
activities shall be submitted to the Client representative one
week in advance on a weekly basis.

4.1.11 Copies of the approved Quality Plan shall be issued to the

Project Manager, QA/QC manager and Procurement
department.

4.2 Quality system procedures

4.2.1 The whole quality system is based on precautionary approach

to achieve quality and contain planning, verification, review and
audit activities at the relevant stages to implement properly.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.2.2 A quality Plan, is prepared for each project describing the

specific requirements of that project
Quality plan is a constituent of project planning.
A quality plan includes:

 Project quality procedures

 Project work procedures
 Inspection & Test Plans.

4.3 Quality System Documents

4.3.1 The Project Quality Plan is the level 1 and governing document of
the quality management system. It makes reference to the scope
of work, project specifications and quality procedures meeting
the requirement of the Project Quality Statement

4.3.2 Quality Procedures employed by COST Company form the level

2 of Quality Management System and are shown in Section 5
Quality Procedures.

4.3.3 Work procedures referred to as Standard Operating Procedures

(SOP) and Inspection and Test Plans form the level 3 documents
are covered in section 6.

4.3.3.1 The work procedures are prepared based on the Project

Specifications.

4.3.3.2 The Inspection and Test Plans and acceptance criteria

are covered in this section.

4.3.4 All quality records generated during the procurement,

construction and pre-commissioning phases of the work form
the level 4 documents. These documents shall be legible and
properly stored and be available and compatible for the
preparation of the Project Inspection Record Book as may be
specified in the contract documents.

Page 12 of 34
 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.4 Contract Review

4.4.1 General
4.4.1.1 Contracts review activities are completed in accordance
with established procedure for construction activities
prior to submitting an offer. Contracts review are carried
out to ensure that all tender documents and contracts
are reviewed to establish that all terms, conditions and
requirements of the clients are clearly defined and
understood.

4.4.2 Review
4.4.2.1 Tender documents are reviewed to determine the
company's ability to meet client requirements. This
review ensures that all relevant data is available and
adequately defined and that assumptions and
clarifications are obtained documented and resolved.
Before dispatch of proposal it is again reviewed with
reference to the check list / list of documents to be
submitted etc, to ensure that client’s requirement is met.
4.4.2.2 QA plan assures that each agreement is reviewed for:
1. Thorough and duly understanding of clients
requirements
2. Complete resolution of differences of understanding
3. Issues that may challenge the capability of COST
to fulfill the intended contract

4.4.3 Amendment to the contract

4.4.3.1 Amendments to the contract are carried out according
to the provisions of the contract. Amendment reviews
are accomplished in a manner similar to the original
contract review.
4.4.4 Records
4.4.4.1 Completed forms from the reviews, are retained.
4.5 Document and Data Control

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.5.1 General
4.5.1.1 All documentations within COST quality system are
controlled by procedures such as:

Control of Quality Document

Drawing Control

4.5.2 Control of Quality Document

4.5.2.1 The Control of Quality Document and Drawing Control

offer for the review and approval as initial release and
subsequent changes. Employees are ONLY to use the
latest revision of documents.

4.5.2.2 Direction for distribution and removal of quality

document
4.5.2.3 including:
1. Distribution to facilitate the effective functioning of
the quality system.
2. Prompt removal of obsolete versions
3. Clear identification of obsolete documents retained
for any reason (e.g. Legal & Financial documents).

4.5.3 Drawing Control

4.5.3.1 Describes the methods to develop and implement a

drawing control and transmittal system for all drawing
received and prepared by COST.

4.5.3.2 Upon approval, a drawing is ready for use. A controlled

distribution list or register is completed to make sure
those related issues of documents and data are available
at all essential locations. Examples of document lists or
registers are:
1. Drawing control register
2. Drawing issue/ return register
3. Bid drawing control register

4.6 Purchasing

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.6.1 General
4.6.1.1 Supply of raw materials, fabrications, spare parts,
specialist services and finished items shall be processed
from the Client approved suppliers.

4.6.1.2 Equipment, materials and services shall be procured

with preference to the Client approved vendors,
subcontractors and independent inspection and testing
agencies.

4.6.2 Supplier Selection and evaluation

4.6.2.1 As stated above, selection of suppliers shall be from the
Client approved vendors and suppliers list as a priority.

4.6.2.2 Alternative sources of materials other than those

identified in the Client’s approved Vendors List, shall be
evaluated, pre-qualified and submitted to the Client for
approval at least two (2) weeks prior to the placement of
purchase order. These alternative sources shall be
evaluated as follows;

1. Suppliers and sub-contractors shall be evaluated on

their capabilities to meet the technical and quality
requirements of the work. It shall include technical
review of products to ensure compliance with
applicable Client standards.

2. Suppliers and sub-contractors shall be evaluated on

their quality system,

4.6.2.3 For suppliers of any equipment requiring an inspection

level of 2 and higher as specified in requirements of the
contract, a physical survey shall be carried out of their
manufacturing sites. Saudi Aramco shall be notified at
least two (2) weeks prior to any planned supplier surveys.
4.6.2.4 Continues monitoring of the supplier performance will be
taken into consideration by recording and monitoring
each dealing output based on the QA/QC verification for
the received materials.

Page 15 of 34
 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.6.3 Requisitions and Purchase Orders

4.6.3.1 Material requisitions and purchase orders shall be
reviewed and endorsed by the QA/QC department when
required to ensure that all pertinent drawings,
specifications and complete information are listed.

4.6.3.2 Suppliers sub-orders shall be reviewed by COST

Company QA/QC personnel to ensure that all relevant
Client technical and inspection requirements as per
required forms are passed to the sub-suppliers.

4.6.3.3 The data contained within purchasing documents

provides the supplier a precise description of the product
ordered, including, where applicable, following essential
elements:

1. Physical description
2. Specifications and standards
3. Delivery lead period
4. Quality requirements

4.6.4 Verification of purchased product

4.6.4.1 Where COST proposes to verify purchased product at the
subcontractor's premises, the COST shall specify verification
arrangements and the method of product release in the
purchasing documents.
4.6.4.2 Where specified in the contract, COST' client or the
client’s representative shall be afforded the right to verify
at the subcontractor's premises and COST' premises that
subcontracted product conforms to specified requirement.
Such verification shall not be used by COST as evidence
of effective control of quality by the subcontractor.

4.6.4.3 Verification by the client shall not absolve COST of the

responsibility to provide acceptable product, nor shall it
preclude subsequent rejection by the customer.

4.7 Control of Client Supplied and Contractor Supplied Materials

4.7.1 Client Supplied Materials

4.7.1.1 All materials supplied by clients for use on a given
contract is inspected upon receipt for damage, quantity,
and conformance with contractual requirements.
Discrepancies are reported to the client for verification
and action.

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QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.7.1.2 A storage area, complete with inventory control records,

is used to ensure that client-supplied materials are
controlled and maintained from its receipt until its
incorporation into the final work.

4.7.2 Contractor Supplied Materials

4.7.2.1 Contractor supplied materials shall be treated like the

client supplied materials in all aspect.

4.7.2.2 Contractor supplied materials shall be segregated from

the client supplied materials to ensure proper tracking
and identification.

4.8 Product Identification and Trace-ability

4.8.1 As per the contract requirement where the code, or
regulations; products are identified through all stages of
design, procurement, receipt, manufacture, installation, repair,
or modification in accordance with the applicable
requirements.

4.8.2 When traceability is required by the contract, the product is

exclusively identified by means of tags, labels, color codes, or
other suitable means.

4.9 Special Process Control

4.9.1 Special process is defined as having results which cannot be
fully verified by inspection and testing of the activity and are
subject to a number of extra rules and safeguards.
4.9.2 Special process shall be controlled with documented
procedures, to ensure that the special requirements are met.

4.9.3 Special Process procedures and personnel qualification as

listed below shall be submitted to the Client for approval as
indicated in the contract, normally at least thirty (30) days prior
to the start of work;
1. Welding procedures
2. Non-destructive testing/examination
3. High Voltage cable splicing/termination
4. Alloy verification (PMI)
5. Coatings

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QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

6. Concrete mix design

7. Cable/conduit seal Installation
8. Gasket Installation
9. Concrete Installation
10. Structural bolt tensioning
11. Gap control for socket weld and back welded threaded
fittings
12. Hydro testing
13. Heat treatment
14. Hot top procedures
15. Refractory Installation

4.9.4 Special processes should be carried out and monitored by

qualified personnel using documented work procedures.
4.9.5 If special process forms a part of quality requirement to all
vendors and sub-contractors, instructions to control special
processes shall be issued to them.
4.9.6 Equipment and personnel qualification records for special
processes are kept current and are available for verification.

4.10 Inspection and Testing

4.10.1 General
4.10.1.1 Quality control plans describe the inspection and testing
requirements to verify that product specifications are met.
Inspection and testing activities are divided into the
following categories:

1. Receiving
2. In-process
3. Final

4.10.1.2 Receiving Inspection

4.10.1.2.1 Receiving inspection and testing is
undertaken on all products upon receipt and
prior to their use.
4.10.1.2.2Documentation and certification accompanying
products are reviewed to ensure
completeness. When products require

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 CONTEMPORARY STRUCTURE CO.
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QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

release prior to verification, both the product

and the appropriate documentation are
marked to reflect the inspection and testing
status.

4.10.1.3 In-Process Inspection and Testing

4.10.1.3.1 In-process inspection and testing is carried
out according to the sequence detailed in the
Quality Control Plan. No release takes place
until all tests and inspections are completed
satisfactorily.

4.10.1.3.2 Prior to the pre-inspection meeting and start

of fabrication of equipment and materials
with an inspection level of 2 and higher, an
“Inspection Assignment Package” shall be
forwarded to the Client twenty-one (21) days
in advance. This package shall include the
following;

1. Complete copy of COST Company’s un-

priced purchase order, sub-contract,
material requisition and attachments
including sub-suppliers un-priced
purchase orders if there’s any.
2. Inspection requirements as specified in
the applicable Client Form(s).
3. Inspection assignment sheet specifying
the inspectors that will perform the
inspection.
4. Inspection and Test Plan.
5. Level of inspection as specified in the
contract documents.
6. Agenda of pre-inspection meeting.

4.10.1.4 Final Inspection and Release

4.10.1.4.1 Final inspection and testing is carried out to
ensure that all requirements have been met,
documentation is complete, and
nonconformance is closed out prior to product
release.

Page 19 of 34
 CONTEMPORARY STRUCTURE CO.
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QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.10.1.4.2 Within fourteen (14) days (or within the period

as indicated the contract) after the acceptance
of equipment or material, a Final Disposition
Report shall be prepared and issued to the
Client. This report shall provide as a minimum
the following;

1. Copies of Client approved waivers.

2. All COST company vendor inspector
witnessed inspections.
3. Copies of supplier’s quality records as
specified in Client Form(s).
4. Copies of NCR’s with final disposition and
resolution.

4.11 Inspection and Test Records

4.11.1 Inspection and test records are maintained in accordance

with the Document and Data Control procedure.

4.11.2 These records include but are not

limited to inspection reports, test certificates, material
certificates, nonconformance reports, and client waivers.
4.11.3 As required, a completed documentation package is issued to
the client with a duplicate copy being retained by the
Company.

4.12 Inspection and Test Status

4.12.1 General
4.12.1.1 Following planned measurements, inspections, and
test;
The inspection and test status of all products is
identified by means of tags, labels, color codes, or
other suitable measures during the various stages of
production.

4.12.1.2 The authority for the application or removal of

inspection

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QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

And test status indicators are stated in the

applicable procedure(s) or quality control plan(s).

4.12.1.3 When required for urgent use, products may be

released prior to verification or testing only under
specific written approval by the relevant authority.
These products are identified showing the inspection
and test status.

4.12.1.4 Any nonconforming product is prevented from

reintroduction into the process until it has undergone
review and disposition.

4.13 Control Of Nonconforming Product

4.13.1 General
4.13.1.1 Procedures and quality plans describe the methods
that ensure nonconforming products are evaluated,
identified, and segregated from the production flow or
installation process.

4.13.2 Investigation and Disposition of Nonconformance

4.13.2.1 Nonconformance are recorded on a
nonconformance report by the person confirming
the existence of the nonconformance and issued to
the person responsible for the area or process
where it exists.

4.13.2.2 An investigation of the nonconformance by the

person responsible for the area or process is
undertaken to determine the effect on quality,
performance, and dependability. The result of the
investigation shall be thoroughly studied and a
corrective and preventive action shall be initiated to
prevent recurrence of the non-conformance.

4.13.2.3 Based on the investigation, the person responsible

for the area or process recommends the disposition
of the non-conformance to the person who controls
the resources for that area or process. Investigation

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

and disposition of non-conforming products

normally results in the following;

1. Rework
2. Accept by concession
3. Re-classify
4. Reject or scrap

4.13.2.4 Where nonconforming product is repaired and/or

reworked or accepted under client concession,
the details are recorded. Re-inspection is carried
out in accordance with the original Quality Control
Plan.

4.13.2.5 Nonconforming products provided by a

subcontractor or by the Client are not accepted.
The item(s) are segregated and moved to a reject
area for subsequent review and disposition.

4.14 Corrective and Preventive Action

4.14.1 General
4.14.1.1 Procedures and quality plans detail the methods
for implementation of corrective and preventive
action to effectively eliminate the causes of actual
or potential nonconformance. The degree of
corrective or preventive actions taken is in
proportion to the associated risks.

4.14.2 Corrective Action

4.14.2.1 When a nonconformance is noted, the person

confirming the existence of the nonconformance
prepares a nonconformance report and a joint
review with the concerned parties is undertaken.
Based on this review, a recommended corrective
action is recorded and submitted to the person
responsible for the activity or area under
consideration for approval.

4.14.2.2 After implementation of corrective action, re-

inspection is conducted to verify compliance.
4.14.2.3 Documented client complaints, once validated
against contract requirements, are subject to the
same process as corrective actions.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

Recommended corrective action is submitted to

the client for acceptance.

4.14.3 Preventive Action

4.14.3.1 Preventive action is initiated for working practices
or activities that have a potential for non-
conformances if the practices are not modified.
4.14.3.2 Reported non-conformances, inspection reports,
audits, and client complaints are analyzed to
detect and eliminate potential causes of non-
conformances.
4.14.3.3 Any employee recognizing the potential for a
nonconformance due to a particular working
practice or activity informs the supervisor who, if
in agreement with the employee report, raises a
nonconformance.
4.14.3.4 The person responsible for the activity or area
under consideration reviews the working practice
or activity and proposes, ensures approval, and
implements preventive action.
4.14.3.5 Verification of preventive action is carried out by
the quality representative of the area or process
and documented on the nonconformance report.

4.15 CONTROL OF MEASURING, TEST AND INSPECTION EQUIPMENT

4.15.1 The Site QA/QC Supervisor and Inspectors shall verify that the
instruments, tools, equipment used in testing, and inspections
are properly calibrated and controlled. All instruments, tools
and equipment shall bear an individual identifying number by
etching or permanently marked on the instrument. Calibrated
control sheet shall be used to document item, identifying
number, location, description, accuracy method, interval, due
date, date calibrated, calibrated by, results and remarks. Any
instruments/equipment found defective and cannot be
repaired shall be replaced and noted in the QA/QC records.

4.15.2 All instruments, tools, equipment used in testing, and

inspections for this project shall be calibrated prior to use
Saudi Aramco approved third party independent testing
agency.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.15.3 Original calibration records / certificates of all tools and

equipment being used on site shall be maintained on file by
the QA/QC department and will be available for review by the
client.

4.15.4 A list of instruments, tools or equipment to be used shall include

but not be limited to;

4.15.4.1 Hydrotest Tools and Equipment.

 Pressure gauges.
 Pressure relief valves
 Testing manifolds

4.15.4.2 Welding Equipment.

 Welding oven with temperature indicator
 Electrode quivers

4.15.4.3 Painting Equipment.

 Elcometer
 Holiday Tester

4.15.5 Sub-Contractor’s Instruments, Tools or Equipment to be

provided:

4.15.5.1 All instrument tools or equipment to be used by

Subcontractor shall be calibrated.

4.15.5.2 Calibration of instruments, tools or equipment

shall be carried out periodically every six months.

4.15.5.3 Copies of calibration records/certificates of all

instruments, tools and equipment being used by
Sub-Contractors shall be submitted to QA/QC
Department.

4.15.5.4 These records/certificates shall be maintained on

file by QA/QC Department and shall be available
for verification.

4.15.5.5 All calibrated instruments, tools and equipment

shall be properly monitored by the QA/QC
Inspectors to ensure that re-calibration is done
before the expiration date.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.15.5.6 A control log for calibrated instruments, tools and

equipment shall be maintained.

4.16 Handling, Storage, Packaging, Preservation and

Delivery

4.16.1 General

4.16.1.1 The COST actions for handling, storage, packaging,

preservation, and delivery of product are thoroughly
documented as per the contract requirement.
4.16.1.2 Material Movement and Protection method describe
the general handling requirements. Standards and
work instructions detail the specific methods of
handling required by COST where applicable as per
contract requirement. The documentation is
improved by training and audit activity.

4.16.2. Storage
4.16.2.1 Material Movement and Protection procedure
addresses general storage requirements. Subject
contract’s Standards and work instructions detail the
specific methods of storage required for that specific
contract and dedicatedly implemented by COST.

4.16.3. Packaging
4.16.3.1. Material Movement and Protection procedure
describes the general packaging requirements.
Specific packing, packaging, and marking
processes are documented as per client’s
format for the individual products.

4.16.4. Preservation
4.16.4.1. Preservation and segregation of product is
addressed under the storage section of Material
Movement and Protection procedure which will
be detailed on contract to contract basis.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.16.4.2. COST shall ensure that completed work quality

is maintained as required in the contract until
project acceptance or delivery.
4.16.5. Delivery
4.16.5.1. COST takes on the responsibility for product
delivery without degradation of product quality.
4.16.5.2. COST shall arrange for the protection of the
quality of product until it is handed over to the
client.

4.17. CONTROL OF MATERIALS AND STORAGE GUIDELINES

4.17.1 All material deliveries on site are to be inspected and

checked by QA/QC Inspectors to ensure that materials are
not damaged or defective and are in conformity with the
material approvals, purchase orders, and packing lists. If
discrepancies are found, it will be reported to the
Procurement Manager through the Project Manager, who in
turn will notify the vendor concerned for corrective measures
or replacements.

4.17.1 Material found acceptable shall be stored in a manner

suited for the particular type of material or in accordance with
the Manufacturer and/or supplier’s recommendations. The
QA/QC Inspectors shall ensure that proper storage of
material is maintained.

4.17.2 The following storage guidelines shall be implemented by the

QA/QC and warehouse staff:

4.17.3 Material testing requirement according to specifications.

4.17.4 Stocked items shall be suitably protected from damage by

spacers or load distribution supports and shall be safely
arranged.

4.17.5 No metal works or materials shall be stored directly on the

ground. Materials shall be properly stored so that they are
not subjected to excessive stresses and that the protective
coatings and finishes are not damaged.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.17.6 Electrical equipment and fittings shall be stored in a locked

warehouse and shall be arranged and labeled to facilitate
easy retrieval.

4.17.7 All materials stored outside that may deteriorate or may be

damaged as a result of direct exposure to weather shall be
adequately covered or protected as recommended by the
manufacturer.

4.18 INTERNAL QUALITY AUDITS

4.18.1 QUALITY AUDIT is a systematic and independent

examination to determine whether quality activities and
related results comply with planned and /or documented
arrangements and whether these arrangements are
implemented and effective in achieving stated objects.

4.18.2 The Project Quality Management system is closely

monitored by QA manager. The audit shall be conducted in
accordance with the Project QA Audit Procedure. COST QA
manager shall organize a planned program of internal quality
system compliance and carry out technical audits.

4.18.3 Each project work phase (procurement, Shop fabrication,

construction and Start-up assistance and / or pre-
commissioning assistance) shall be subjected to audit, Audit
schedules shall be as per contract requirements.

4.18.3 Quality audit shall be carried out as per attached schedule.

4.18.4 Auditors shall have good experience in QA/QC inspection or

auditing experience and be able to exercise judgement
against the criteria of the standards.

4.18.5 The Client representative shall be notified of all scheduled

audits two weeks in advance.

4.18.6 Audit reports shall be submitted to the Client within fourteen

days of its completion.

4.19 Audit Planning and Execution

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.19.1 An audit notification memorandum is sent to the area to be

audited, giving the basis and a suggested date and time for
the audit.
4.19.2 A detailed audit scope is issued detailing the area to be
audited and confirming the information requested in the audit
notification.
4.19.3 The audit is executed.
4.19.4 Audit report is issued and includes identification of non-
conformances, which are subsequently returned with auditee-
suggested corrections and/or corrective actions.

4.19.5 A follow up audit is conducted to verify implementation of

corrections and corrective actions.
4.19.6 The results of audits are used in the Company’s continuous
improvement process and form part of the Company
Management Review.

4.20 Training

4.20.1. General

4.20.1.1 The success of the Company is dependent upon

its ability to employ and retain qualified individuals
and carry out a program of continuing education
to improve performance and enable employees to
update with new skills.

4.20.1.2 Supervisors, Managers, and individuals are

responsible for identifying training needs. These
training needs are assessed and agreed upon
both during employee performance evaluations
and at other times on an as-needed basis. This
allows the supervisor and the individual
concerned to determine areas needful of
improvement or further training.

4.20.2. Training Objective

4.20.2.1. Training objectives are achieved by close cooperation
between the supervisor and the individual to establish
suitable training methods.

4.20.1.1 The management providing maximum benefit to

the individual and the Company subsequently
endorses these.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.20.1.2 Managers and supervisors assure that suitable

training is available within their area of
responsibility.

4.20.1.3 The impact of training is reviewed and recorded

as part of the Company management review.

4.20.1.4 The Company recognizes the importance of

individuals obtaining certification in their fields of
expertise and encourages participation in
professional societies.

4.20.1.5 Quality awareness training is provided to all

employees to keep them informed of current
quality requirements within the Company.

4.21 Statistical Techniques

4.21.1 Identification of Need

4.21.1.1 None of the present company activities warrant
anything other than the most basic of statistical
techniques and these are indicated within the
integrity of the quality procedures i.e. (project plans,
quality plans and quality control plans).

4.21.1.2 Be that as it may, these statistical techniques will be

kept under review and considered each year as part
of the agenda for the Quality System Review and
improvement.

4.22 Servicing
Servicing is limited to services carried out during defect liability period
or warranty period for the projects carried out by COST. Since
maintenance shall be handled on case to case basis, it is not
applicable to make a documented procedure to describe each case,
but it shall be done as follows:

4.22.1 Warranty period is generally one year or as specified in

the contract.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.22.2 If there is any defect or requirement for maintenance by

client after project completion, the request shall be
forwarded to the respective Manager.

4.22.3 The Project Manager shall initiate the action based on

contractual obligation and issue memorandum to the
respective personnel for implementation.

4.22.4 The Project Manager shall ensure that the client

requirement in maintenance is resolved and handed over.
Final report of hand over shall be given to the client and
the Senior Management of COST.

4.22.5 Should servicing become a specified requirement, COST

will establish and maintain documented procedures for
performing, verifying and reporting that servicing activities
meet the specified requirements.

4.23 QA/QC Reports

4.23.1 The Site QA/QC inspector shall prepare a Daily Report at the
end of each working day containing all inspections/tests made
on the report day including:

4.23.1.1 Significant construction underway (i.e. earthwork,

concreting, pipe work, heavy lifts In-plant, etc.).

4.23.1.2 Location of inspections and/or tests made.

4.23.1.3 Result of inspections, highlighting nature of

deficiencies observed & corrective actions taken, or
to be taken. Sign off, like pour cards, etc., shall be
submitted with this report.

4.23.1.4 Reports of tests performed with results, including

computations (if required). Where test results can
not be completed at the time a report is submitted a
notation shall be made that a test was performed
and the approximate result described. Delayed test
results shall be submitted with this report on the
date received.

4.23.1.5 Results of inspections made on material and

equipment upon arrival at job site & prior to
incorporation into permanent work. Compliance
with approved submittal, purchase order, packing
list, or MTO. The form/card shall be filled out by the

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

QA/QC inspector upon arrival of material or

equipment on site and shall include a report on
damage and disposition with recommendation for
storage.

4.23.1.6 The Site QA/QC Supervisor shall consolidate the

above reports at the end of the week as an
attachment to the Daily QA/QC Report.

4.23.2 The Weekly Report shall include the following:

4.23.2.1 A summary of the week's inspections highlighting

problem areas and solutions.

4.23.2.2 A summary of test results for the week with copies

of graph/charts, tabulations, weekly rates, etc, as
required or developed for trend and problem
analysis.

4.23.2.3 A report on the Quality Control program addressing

discussions with client representatives on
procedure improvements, changes etc.

4.24 Quality Management Report

A monthly Quality Management Report shall be submitted to the

Client. The report shall include the following as a minimum;
 Listing of supplier surveys performed with summary of
findings.
 Listing of Pre-inspection meetings conducted.
 Listing of supplier inspections performed versus
scheduled inspections.
 Non-conformance reports issued to vendors.
 Non-conformance reports issued during construction;
number issued, closed out and pending for the month.
 Listing of quality audits completed (internal and
subcontractor).
 Listing and disposition of all defective or rejected material
or equipment received at job site by COST and
subcontractor.
 Welding rejection rate reported in a per joint basis for
piping, structural and alloy welds. A chart showing the
historical performance during the project shall be
included.
 Listing and status of all engineering waivers.
 QA/QC personnel listing by discipline.

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 CONTEMPORARY STRUCTURE CO.
FOR CONTRACTING
QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.25 INSPECTION NOTIFICATION

4.25.1.1.1When a particular phase of work needs to be inspected /

tested, the QA/QC Inspector shall submit a Request for
Inspection (RFI) to the Client Projects Inspection Unit on a 24
hours notice during normal working days and 48 hours on
weekdays prior to the scheduled date of inspection using the
Client Request for Inspection Form(s).

4.25.2 The inspection notification will be done in two parts as follows:

 Construction Group through the Site Engineer shall request

for inspection, as per the approved Inspection and Test
Plan, to the QA/QC Department using an Inspection
Request Form.
 Upon satisfactory completion of the in-house inspection
as per the checklist, a request for inspection (RFI) will
be submitted to the Client Project Inspection Unit.

4.26 Control of QA/QC Documents

4.26.1 The Site QA/QC Supervisor shall establish and maintain the
following records and files. It shall be his responsibility to see
and check that these records are properly maintained and
stored up to the project completion.

4.26.1.1 A record of all tests filed sequentially and by work

categories. All tests including but not limited to the
following shall be controlled and properly
documented, (Materials, Soil, Concrete and NDT).

4.26.1.2 A record of Daily and Weekly QA/QC Reports.

4.26.1.3 A record of all vendors and technical approvals filed

correlatively by submittal number and index.

4.26.1.4 A file of current and governing contract drawings

and specifications, variation orders, shop drawings,
and technical standards issued for construction. A
document control clerk on-site will log and track the
latest governing data and drawings and ensure
proper issuance of the same.

4.26.1.5 A file of signed off QA/QC Inspection Forms.

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Stevedoring Bldg.

4.26.1.6 Contract materials receiving report file.

4.26.1.7 A record of properly logged and closed non-

conformance reports.

4.26.1.8 A separate set of approved drawings for noting

down the changes done in the job site which will be
incorporated on the “As-Built” drawings.

4.26.2 The above QA/QC documentation shall be in English language

and of legible and micro filmable quality for easy
processing/reproduction.

4.27 Pre-commissioning Phase Quality Control Activities

4.27.1 Pre-commissioning activities comprise all inspection and test

activities for a system component to check its completeness,
operability and readiness for commissioning and start up of
the system.

4.27.2 All the pre-commissioning quality control activities are

contained in the Inspection and Tests Plans.

4.27.3 Prior to the Client’s acceptance of the work, the following

shall be accomplished;

 All inspection and tests requirements shall be properly

and satisfactorily done.
 All non-conformances have been corrected.

4.28 Technical Queries

4.28.1 In cases where a deviation or changes is proposed in the

construction drawings, method of installations, type of
materials and others which still conforms to the requirements
of the Client Standards and Specifications , a technical
query shall be submitted to the Client Representative for
review and approval.

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 CONTEMPORARY STRUCTURE CO.
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QA / QC Manual Contract No. 3000775497

Renovation of Tanajib Port Control tower and

Stevedoring Bldg.

4.28.2 Any changes resulting from approved Technical Queries

shall be incorporated into the final as-built drawings.

4.29 Waivers

4.29.1 Any deviation from Mandatory Client Engineering

Requirements a Waiver shall be obtained in accordance with
engineering procedures.

4.29.2 Requirements of any approved Quality Plan or ITP previously

approved by the Client shall not be waived without the
express written consent of Client Representative.

4.29.3 A log detailing all waivers from the Client or COST QA/QC
and inspection requirements obtained during all wok phases
shall be maintained by COST. This log must indicate the
status of the waiver, a brief description and details of the
applicable purchase order and equipment or construction
process.

4.29.4 A log detailing all technical waivers to the Client’s standards,

including those initiated by the Client (during or prior to the
start of the Work) or by COST shall be maintained. This log
must indicate the status of the waiver, a brief description and
details of the applicable purchase order and equipment or
construction process.

4.30 Geo-technical/Soil Investigation.

4.30.1 Prior to the start of civil construction activities a Geo-

technical/soil investigation report shall be submitted to the
Client for review and approval.

4.31 Compliance to the Client Standards and Specifications

The Quality System shall be in compliance with the applicable

Client Material Specifications (SAMSS), Client Engineering
Standards (SAES) and other Client standards and specifications.

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