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Quality Management
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MCQ Quality-Management — Better Than Ever
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Process Control:
The concrete batching plant is fully automated and the process as well is recorded
and equipped with a self controlling system. The required concrete mix and quantity
are activated, and the weighing process starts. All raw materials are added cumulative
to 3 weighing hoppers, one for cement, one for aggregates and one for crushed
ice. The weighing is only accepted by the plant control system if all items have been
batched within a certain tolerance. In case of tolerance violations, the batching process
is stopped automatically and error indicated.
The liquid additives such as plasticizer and retarder are batched in cylinders with an
automatic control system. Should the quantity of the individual additive not be within
the required tolerances, the batching process is stopped automatically and the error
will be indicated.
The correct amount of all raw materials is released into the mixer and water is added
by a water pipe with an electronic flow meter. The required quantity of water has to
be added within a certain time period. In case of any errors in quantity or time, the
batching process is stopped automatically and error indicated.
All data from batching of raw materials, liquid additives and water are recorded by the
computer and are printed in the batch document.
Furthermore all silos and bins are equipped with electronic filling indicators to optimize
the control and organization.
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Inspection and Testing:
All raw materials are tested by the staff of the quality control laboratory prior to dumping
or unloading for quality and consistency. In addition, frequent tests are carried out
on all raw materials in accordance with the relevant standards in our quality control
laboratory. All test results are recorded. Any tolerance violation will be reported immediately
to the plant management as well as to the customer.
Frequent tests will be carried out in our quality laboratory for ingoing materials as follows:
- Tests on aggregates include shape, density, grading line, chemical analysis,
dust content, contaminations and temperature.
- Tests on cement and puzzolanic materials include fineness, density, initial
and final setting, compressive and flexural strength, temperature.
- Tests on water and ice such as chemical analysis, value of pH, temperature.
Tests on chemical additives will be carried out on a reference mix for
performance.
- All data will be recorded, any tolerance-violence immediately reported to
the plant management and the customer. A copy of these records will be submitted
to the customer frequently.
- There will be carried out tests on each outgoing concrete regarding temperature
and initial slump
All tests on fresh and hardened concrete will be carried out in accordance with the
regulations of the contract as well as the relevant standards.
Control of Measuring and Test Equipment:
The weighing devices of the plant will be checked frequently for correct measurement
using officially authorized weights and approved weighing scales. These tests will be
carried out once a month and all data will be recorded and submitted accordingly. In
case of any occurring problem these tests will be carried out every 14 days.
Our quality control laboratory is able to perform all relevant tests on raw materials
as well as the fresh and hardened concrete. Procedures and equipment are regularly
checked according to the relevant standards. These checks also include plant equipment.
Material identification:
All concrete trucks leaving the batching plant do have a delivery document which
clearly identifies the type of concrete, the batch number, date and time of batching,
initial concrete temperature and initial slump as well as the latest time of unloading.
Control of Non-confirming Material and Concrete:
As initial tests will be carried out on all incoming raw material, it should be possible to
keep the number of non-confirming material at a minimum. However, we will clearly
mark an area, where such material has to be dumped. Further regulations will be discussed
with our suppliers.
In case of any tolerance violation of the concrete and in case of a violation of the maximum
time limit for unloading the fresh concrete has to be dumped in a clearly marked
area. Moulds will be prepared to form blocks of concrete, which can be transported
by trucks.
All dumped material, raw material and as concrete will be recorded in a book accordingly
Records Control and Audits:
All data will be recorded in specific books as well as in computer programs. Should
there occur any problem or violation, the plant management will be informed immediately.
There will be a daily meeting of quality and plant management, and the records
of data will be discussed and signed.
Frequently this book of records will be presented to the customer, data will be discussed
and the books signed.
A copy of the computer program with records will be submitted to the customer frequently.
Ordering Procedure of Raw Materials:
The plant management orders raw materials according to the demands.
There will be a minimum of two days production material in stock at all times.
Any problems occurring with raw materials or concrete will be reported immediately to
the plant management, therefore quality control personnel
do not have to be involved in the ordering process.
Ordering Procedure of Concrete:
The customer is asked to present a plan with the required concrete for the next three
days in order to optimize procedures in the batching plant. However, minor changes
will always occur and will be dealt with, as the reality of sites does not exactly follow
a three day plan.
In addition, the customer is asked to submit a daily plan for required concrete confirming
type of concrete, point of delivery, time of unloading and individual quantities.
Training of Personnel:
The personnel of the batching plant as well of the quality control laboratory are experienced
professionals, familiar with the required work. However, there will be frequent training
sessions, where personnel will be updated.
Furthermore we offer training for customers in terms of perfect compacting and curing
of concrete, which is an important for the performance of the designed concrete.
Maintenance Process:
The batching plant is designed to operate 24 hours a day, most items of maintenance
can be carried out during normal operation. However, there will be a weekly inspection
on all parts of the plant that are subject to wear and tear. A weekly check is set up for
repairs and change of damaged parts.
Example of Statistic View:
In the installed control system we get a complete report regarding the plant. We register
every motor, every valve, the silos, production and interruption during production.
In the statistics we see all the production details such as operation time, output per
hour, per day, per week, per month and per year. We see every occurrence and also
the reason why. These statistics can be handed over to the customer.
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| Projects Overview |
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Jan De Nul Dredging Ltd., Boskalis Westminster Middle East Ltd
Boskalis is building this mega LNG harbor in cooperation with dredging company Jan de Nul. The total contract value is approximately USD 2 billion in which Boskalis has a 50% share.
more... |
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