Quality Plan Gosford Passing Loops Project

Gosford Passing Loops Project
GPL-01-D&C
Quality Management Plan

Document Number GPL-DWNR-PM-000110
Revision A

Revision A
Document Details
Submission information
This document and its contents have been prepared by Downer and are intended solely for
Transport for New South Wales (TfNSW) information and use in relation to the Gosford Passing
Loops (GPL) Project.
Document Preparation & Control
Document Review
Elisha Howells Quality Officer
Sheree Jones Quality Manager GPL
Document Approval
Signature
David Burkitt Project Director
Revision Status
Rev
Date
28-03-13
Associated documents
Document Number
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Title
Revision
Date
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TABLE OF CONTENTS
terms and definitions ________________________________________________________________________ 5
1 introduction _____________________________________________________________________________ 7
2 purpose of the quality management plan (QMP) __________________________________________ 8
3 project description _______________________________________________________________________ 9
3.1 operational project purpose ________________________________________________________ 9
4 project milestones ______________________________________________________________________ 11
5 management representative ____________________________________________________________ 13
6 quality document control _______________________________________________________________ 14
6.1 introduction document control _____________________________________________________ 14
6.2 document storage ________________________________________________________________ 14
6.3 plan review _______________________________________________________________________ 14
6.4 revisions and amendments _________________________________________________________ 15
6.5 qmp submission ___________________________________________________________________ 15
6.6 control of quality records __________________________________________________________ 15
7 communicating the qmp _______________________________________________________________ 16
8 qmp references ________________________________________________________________________ 17
8.1 general ___________________________________________________________________________ 17
8.2 legal and regulatory _______________________________________________________________ 17
9 downer australia integrated management system (IMS) ___________________________________ 18
9.1 structure of the IMS ________________________________________________________________ 18
9.2 audit of the ims____________________________________________________________________ 19
10 project quality objectives, organisation & resources _______________________________________ 20
10.1 introduction _______________________________________________________________________ 20
10.2 quality management objectives ___________________________________________________ 20
10.3 project organisation chart _________________________________________________________ 21
10.4 project responsibilities______________________________________________________________ 21
11 project administration ___________________________________________________________________ 26
11.1 project filing and storage system ___________________________________________________ 26
11.2 project meetings, reviews and reports ______________________________________________ 26
11.3 construction programme __________________________________________________________ 26
11.4 control of drawings and specifications ______________________________________________ 26
11.5 managing variations _______________________________________________________________ 26
12 internal audits and planned inspections __________________________________________________ 27
12.1 project audits _____________________________________________________________________ 27
13 purchasing _____________________________________________________________________________ 28
13.1 suppliers and subcontractors _______________________________________________________ 28
13.2 site induction and training _________________________________________________________ 29
13.3 plant and equipment ______________________________________________________________ 29
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14 product and service control _____________________________________________________________ 30
14.1 project control documentation ____________________________________________________ 30
14.2 product identification and traceability ______________________________________________ 30
14.2.1
Identification ______________________________________________________________ 30
14.2.2
Traceability _______________________________________________________________ 30
14.3 handling and storage of construction materials _____________________________________ 30
14.4 inspection and test equipment _____________________________________________________ 30
14.5 control of non-conforming materials or work ________________________________________ 31
14.6 design control _____________________________________________________________________ 31
15 inspection and testing __________________________________________________________________ 32
15.1 itp compliance ____________________________________________________________________ 32
15.2 control and storage of itps ________________________________________________________ 32
15.3 management of itps ______________________________________________________________ 32
15.4 principal itp requirements __________________________________________________________ 32
15.5 development of itps ______________________________________________________________ 32
15.6 management of itps and lot checklists _____________________________________________ 33
15.7 hold points and witness points ______________________________________________________ 33
15.8 non-conformances ________________________________________________________________ 33
16 cleaning and protection of work_________________________________________________________ 34
APPENDIX A: IMS ACCREDITATION CERTIFICATES _______________________________________ 35
Appendix B: DOWNER AUSTRALIA BUSINESS POLICY ____________________________________ 36
Appendix C: HOLD AND WITNESS POINT REGISTER ______________________________________ 37
Appendix D: AUDIT AND REVIEW SCHEDULE ___________________________________________ 38
Appendix E: INDEX OF QUALITY PROCEDURES AND FORMS _____________________________ 39
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TERMS AND DEFINITIONS

Term or
Acronym
Definitions
CAR
Acronym for Corrective Action Request (CAR) is raised when a process or

service is not performed in accordance with specified requirements resulting
in a failure of the process, service or product. Corrective action may result
from an incident or from findings during an audit.
CEMP
Acronym for Construction Environmental Management Plan
CMP
Acronym for Contract Management Plan identifies how DA will deliver all
requirements within contract GPL-01-D&C. The plan provides an overview of
all of the management plans that will be developed and executed for the
duration of the project.
CLP
Acronym for Community Liaison Plan
CoA
Acronym for Conditions of approval
Compliance
audit
Verification of how implementation is proceeding with respect to a

construction environmental management plan (CEMP) (which incorporates
the relevant approval conditions).
CSMP
Acronym for Construction and Site Management Plan
DA-QA-FM
Document code for Downer Australia Quality Management Form
DA-QA-PR
Document code for Downer Australia Quality Management Procedure
DA-QA-RG
Document code for Downer Australia Quality Management Register
DA-QA-RI
Document code for Downer Australia Quality Management Record
DA-QA-TR
Document code for Downer Australia Quality Management Training

Resource
DirectorGeneral
Director-General of the NSW Department of Planning and Infrastructure (or

delegate)
DMP
Acronym for Design Management Plan
Downer
Downer Australia
DP&I
Acronym for Department of Planning and Infrastructure
EMP
Acronym for Emergency Management Plan
GCC
Acronym for Gosford City Council
Hold Point
Those points identified within the applicable Inspection and Test Plan,
beyond which the stated activity must not proceed within approval to
proceed from the nominated authority.
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Term or
Acronym
Definitions
IMS
Acronym for Integrated Management System
Lot Checklist
Checklist to record performance and outcomes of project inspections and

testing
ITP
Acronym for Inspection and Test Plan.
Noncompliance
Failure to comply with the requirements of the Project approval or any

applicable license, permit or legal requirements.
Nonconformance
(NCR)
Failure to conform to the requirements of Project system documentation

including this CEMP or supporting documentation.
NSFC
Acronym for Northern Sydney Freight Corridor
NCR
Acronym for Non Conformance Report
Plan
A document setting out the specific practices, resources, activities and

responsibilities relevant to a particular project or contract.
Principal, the
The Project Principal Transport for NSW
Project, the
The Gosford Passing Loops Project
QA
Acronym for Quality Assurance. It refers to the planned and systematic

activities implemented under the Quality Management Plan.
QMP
Acronym for Quality Management Plan
REF
Acronym for Review of Environmental Factors, environmental assessment

prepared under Part 5 of the EP&A Act.
Stakeholders
Key Project Stakeholders.
SWMS
Acronym for Safe Work Method Statement
TfNSW
Acronym for Transport for NSW
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1 INTRODUCTION
The Northern Sydney Freight Corridor (NSFC) Program is an initiative to improve capacity and
reliability for freight trains on the Main North Line between Sydney (Strathfield) and Hexham, west
of Newcastle.
The program is designed to:
Improve freight train access through northern Sydney
Relieve a serious bottleneck on the rail network
Create a more efficient freight rail network
Improve the reliability of passenger services on the Main North Line
Enable freight access during peak times
The Gosford Passing Loops project (the Project) is one of four projects as part of the wider NSFC
Program.
In October 2012, the Project was approved by the Deputy Director General Transport Projects,
Transport for NSW subject to Conditions of Approval (CoA).
In January 2013, Transport for NSW (TfNSW) appointed Downer EDI as the design and construct
contractor for the project.
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2 PURPOSE OF THE QUALITY MANAGEMENT PLAN (QMP)

This Quality Management Plan (QMP) identifies the project specific management structure,
resources, procedures and practices that Downer will implement for the following project:
Contract Number: GPL-01-D&C, Gosford Passing Loops
These controls will provide for the management of all issues relating to the quality of work and
delivery of the project.
This QMP has been developed to satisfy the technical requirements of the Contract and the
requirements outlined within TfNSW Standard Requirements (TSR Q1 Quality Management).
The development and execution of the QMP is guided by and complies with the Downer Australia
Integrated Management System (IMS). The IMS satisfies required international and national
standards, specifically AS/NZS ISO 9001:2008 and includes all of the Downer Australia quality
documentation.
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3 PROJECT DESCRIPTION
The Project comprises the construction of two electrified passing loops and associated
infrastructure north of Gosford Station to allow for the passing of faster passenger trains while
freight trains are held on the mainline or in the reverse arrangement as deemed necessary.
The Project comprises two new tracks for the passing loops (and associated overhead wiring, civil
and structural works) between Gosford and Narara stations. The total new track length would be
approximately 4 kilometres (km) (approximately 2 km for both the Up and Down Refuges). The
new tracks would be constructed on the outside of the existing rail tracks and would generally be
accommodated within the existing rail corridor boundary (with the exception of a short section of
track between chainages 82.40 km and 82.70 km, which would require the eastern corridor
boundary to be widened by up to approximately 3 metres to facilitate the construction of the
track and other railway infrastructure).
The key features of the GPL include:
Three new pairs of bridges (six bridges in total) over Bradys Gully, Wingello Creek and Wyoming
Creek, adjacent to the existing rail bridges.
One new crossover on the Up Main (adjacent to Brooks Avenue, Wyoming, between chainages
83.50 km and 83.80 km) and one new turnout on the Down Refuge (adjacent to Brooks Avenue,
Wyoming, between chainages 83.60 km and 83.80 km).
Maintenance access roads and gates.
A combined services route (approximately 2 kilometres long) on the eastern side of the rail
corridor between Gosford Station and the Etna Street overbridge, and on the western side of the
rail corridor between the Etna Street overbridge and Narara Station.
Three underline crossings (buried services route allowing services/utilities to cross beneath the rail
tracks) and associated cable routes at proposal chainages 81.54 km, 81.97 km and 84.52 km.
The refurbishment of an existing Up Refuge between Gosford Station and the Etna Street
overbridge the removal of two existing maintenance sidings (referred to as the Down Loco Sidings
1 and 2), adjacent to Gosford Showground.
The removal of two existing crossovers and one turnout between Gosford Station and Gosford
Showground.
The refurbishment of one existing catchpoint adjacent to Gosford Showground.
Modifications to the existing signalling system at various locations between Gosford Station and
north of Narara Station (proposal chainages 81.00 km to 86.00 km).
The adjustment, relocation, protection and/or provision of services and utilities, including
overhead wiring, high and low voltage, telecommunications/control, and earthing/bonding
operation of the Project.
3.1
OPERATIONAL PROJECT PURPOSE
The fundamental purpose of the Gosford Passing Loops Project is to provide an alternative route
for freight trains, allowing them to be passed by faster passenger rolling stock.
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The operational purpose of the Gosford Passing Loops Project is to:
Improve the operational reliability of the RailCorp network, for the benefit of both freight
services and passenger services
Improve the ability of the RailCorp network to recover from operational incidents
Make allowance for known future projects
Achieve compliance with relevant legislation
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4 PROJECT MILESTONES
For major project milestones, refer to the GPL Program that will be submitted as part of the
monthly report.
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Figure 1 Project Overview
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5 MANAGEMENT REPRESENTATIVE
The nominated Quality Management Representative for the Gosford Passing Loops Project is:
Name: Sheree Jones
Title: Quality Manager
Phone: 02 4918 7400
Mobile: 0418 493 503
Facsimile: 02 4918 7404
The Management Representative is contactable by telephone and/or email at all times during
the undertaking of the Contractors Activities and must be available to attend meetings at the
Principals office or at the Site within 48 hours of notice by the Principals Representative.
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6 QUALITY DOCUMENT CONTROL

6.1
INTRODUCTION DOCUMENT CONTROL
This document is authorised, distributed, amended and reviewed in accordance with DA-QAPR001 Document Management (included within the IMS). Records of distribution are maintained
by the Quality Manager.
All controlled copies of this document are registered in accordance with DA-QA-PR001
Document Management.
6.2
DOCUMENT STORAGE
Hard Copy Storage and Distribution

A hard copy of this document shall be maintained within the site office for the duration of the
project and may be accessed by employees, sub-contractors, Health and Safety Representatives
and project personnel.
Downer Electronic Document System
An electronic copy of the QMP and associated quality documentation will be stored within the
following project files held within the Gosford Project Server.
All Inspection and Test Plans (ITPs) and supporting information and evidence will be recorded
and stored in the Quality Database QAntrol.
Principal Electronic Document System
The principal has nominated the TeamBinder system as the channel for the sending and receiving
all documents, drawings, specifications and correspondence between the Principal and the
Project Team.
Documents to be stored within TeamBinder include all project administration, reports, plans,
drawings, O&M manuals, technical maintenance plans, services schedules and certificates
directly related to the project.
TeamBinder is available to the Project Team who are required to attend training to ensure
effective management of the document management system.
The Quality Manager will ensure that a master copy of the QMP and associated documentation
will be uploaded to TeamBinder and distributed to nominated Downer and Principal
Representatives.
6.3
PLAN REVIEW
This document shall be reviewed in response to reported issues and outcomes of internal or
external audits and/or changes to internal policies. In particular, a review will address:
Progress of Works
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Changes in project scope and/or timing
Changes in quality documentation requirements (i.e. new process that requires new
documentation)
Non-conformances and corrective actions raised as a result of audits or observations
6.4
REVISIONS AND AMENDMENTS
Revisions
All document revisions shall be made in accordance with DA-QA-PR001 Document Management
and with the authority of the Quality Manager.
Amendments
Amendments are only made as permitted under the contract.
When amendments are made, the entire document will be reissued and the revision number
updated. Registered recipients will automatically receive the new revision with advice on
amendments made.
Revised plans and associated documents will be issued together with a transmittal form and
recipients will ensure superseded versions are replaced and destroyed to prevent inadvertent use.
6.5
QMP SUBMISSION
The QMP will be submitted to the Principals Representative for review in accordance with the
requirements set out in the Contract.
6.6
CONTROL OF QUALITY RECORDS
The following controls will be implemented to manage quality records for the duration of the
project and for a period of five years from the Date of Completion. These controls satisfy TfNSW
quality requirements, and have been taken from TfNSW Standard Requirements TSR Q1 Quality
Management.
Downer will ensure that all quality records satisfy the requirements of the Contract
Downer will retain all product and service conformance records including the
Subcontractors service conformance records and certificates for a period of no less than
five years from the Date of Completion
All records will be made available to the Principal.
Where there is a requirement to forward records to the Principals Representative, Downer

will submit one original and three copies (one of which is unbound) of each document. In
addition to this an electronic copy on DVD/CD in PDF and native formats will be submitted
as required.
Where requested by the Principals Representative, Downer will provide the Principals
Representative with copies of any Quality Records. Those Records which are not available
on-site, will be forwarded to the Principals Representative within 3 business days of the
request.
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7 COMMUNICATING THE QMP

All project personnel are required to complete induction training prior to the commencement of
site works. The quality induction training will address:
1/ the content of the QMP and the specific quality responsibilities and obligations of project
personnel
2/ performance objectives and outcomes related to inspection and testing, and required record
keeping
3/ required management of non-conformances (NCR) and required reporting
The quality induction will form part of the Safety, Environmental, Community and Quality
Induction.
A record of quality inductions will be developed and updated monthly for the duration of the
project.
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8 QMP REFERENCES
8.1
8.2
GENERAL
Contract GPL-01-D&C (Gosford Passing Loops Project)
TfNSW Standard Requirements TSR Q1 Quality Management
TfNSW Inspection and Test Plans Minimum Requirements
TfNSW Project Compliance and Assurance 9TP-ST-020/4.0
IMS and Applicable Downer Quality Procedures and Forms
GPL Construction and Site Management Plan (CSMP)
GPL Design Management Plan (DMP)
GPL Contract Management Plan (CMP)

LEGAL AND REGULATORY
Legal and Regulatory compliance documents are managed within Downer Australia using a
number of centralised reference matrices. These detail the references applicable to all aspects
of the work to be carried out in the course of this contract.
Functional Area
Applicable Matrix
Environment
Health and Safety
DA-QA-FM007.4 Relationship of IMS to AS-NZS-ISO Standards
Quality
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9 DOWNER AUSTRALIA INTEGRATED MANAGEMENT SYSTEM

(IMS)
The Downer Australia Integrated Management System (IMS) is a business management system
that guides and controls all processes required to carry out the business. The IMS satisfies the
following International and National standards:
AS/NZS ISO 9001:2008 Quality Management Systems - Requirements

AS/NZS 4801:2001
Occupational Health & Safety Management System
AS/NZS ISO 14001:2004
Environmental Management System
Australian Government Building and Construction OHS Accreditation Scheme
9.1
STRUCTURE OF THE IMS
The core of the IMS is a set of Downer Australia documents that reflect processes conducted
across all Australian business units. Key documents at the national level are:
Strategies, Objectives and Policies guide our business and how we conduct operations
Management Standards (MS) are the core national standards that cover the business
processes and risk controls. They describe the systems, methods and forms that are used to
plan, manage and control our processes and risk controls. They also define the minimum
standards we apply to our worksites in the areas of Health, Safety and the Environment
Handbooks provide information on how the IMS is used and operates and provide
specific information in key areas
Forms, Zero Harm Notifications, Risk Assessments, SWMS and other documents are the
details of the work we do, help control our risks and provide records
The IMS is hosted on the Downer Australia intranet, a business application available to all
employees and providing a set of key resources including:
Document management
Records management
Risk management
Incident reporting and investigation
Non-conformance management
Training provision and record management
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9.2
AUDIT OF THE IMS
The IMS is audited, and has been certified by, by an accredited 3rd Party organisation to verify
compliance with the above standards as well as legislative and regulatory requirements. A copy
of the certificate confirming the currency of certification is provided in Appendix A, and a
summary of the certification is reflected in the following table.
Compliance Area
Accreditation Standard
Audit Authority
Certificate Number
Quality Assurance
AS/NZS ISO 9001:2008
BVQI SAI Global
149150 QEC7718
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10 PROJECT QUALITY OBJECTIVES, ORGANISATION &

RESOURCES
10.1 INTRODUCTION
Downer Australia is engaged in Australia wide engineering and project management of
infrastructure including design, construction and maintenance services (civil, rail, electrical,
instrumentation, telecommunication and power generation).
The Downer Australia vision is to be regarded as an industry leader in these chosen fields which
will be achieved by focusing on the following business goals:
Ensuring clients are satisfied with our service and performance
Observing and fulfilling statutory obligations and client specifications
Achieving Shareholders expectations
Ensuring employees are accountable, motivated and perform to their full potential
This project will achieve these goals by ensuring all contractual obligations and specified
standards are met.
10.2 QUALITY MANAGEMENT OBJECTIVES
The Quality Management objectives for this project include:
Key Result
Area
Quality
Management
Project Quality Objectives
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All personnel engaged on the project

have appropriate training and have
demonstrated competency required to
meet the quality obligations of the
project
Monitor quality through a formal program
of inspection by those responsible for the
quality of work
Ensure that planned quality control
programs are being carried out through
a series of audits conducted by
personnel not responsible for the day to
day delivery of works
Performance Measures &

Targets
All work complies with the

quality requirements of
the contract
No loss in time and cost

due to rework or
replacement
All defects identified and

resolution agreed without
delay to contract works
There are no negative

observations or
Corrective Actions as a
result of client audits
Ensure all quality documentation used by

those responsible for inspection is being
completed, controlled and stored as
outlined within the QMP
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10.3 PROJECT ORGANISATION CHART
Refer to the CMP for the project Organisational Chart.
10.4 PROJECT RESPONSIBILITIES
Project Manager
The Project Manager (Greg Barnes) has responsibility for the timely execution of the project in
accordance with contract requirements, the Downer IMS, safety, environment and quality
procedures, including client and authority requirements. The following table details this
responsibility:
Area
General
Communication
Systems of Work
Description of Responsibility
Be familiar with legislation and codes of practice relevant to this role
Work is completed as per Contract Gosford Passing Loops GPL-01-D&C
Hold points are signed off on after completion of relevant task
Client CARs/ Non-Conformances are actioned promptly
Requirements of the CSMP are communicated to all personnel, sub

contractors and, where appropriate visitors to site
Chair regular meetings between the project team
Distribute information pertaining to the project is distributed amongst the

workforce
Direct communication with and reporting to the Principals Representatives
Implement systems of work in accordance with statutory obligations and

the Downer IMS
Oversee sub contractors performance of all work in accordance with

statutory obligations and the Downer IMS.
Liaise with the Safety, Environment & Quality Manager on any unique
activities that may require special operating standards or supervision.
Employees are licensed where required and are competent.
All supervisory personnel are fully instructed in the requirements of any

statutory obligations and relevant procedures contained within the IMS.
Record any client induction requirements in accordance with MS006

Training Awareness & Competency and any Principal requirements.
Implement Zero Harm (Safety and Environment) Management in

accordance with the Zero Harm Management Plan (ZHMP)
Training
Zero Harm
(Safety &
Environment)
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Project Engineers
The project engineers are responsible for technical support including planning, managing and
controlling the project activities to ensure delivery of quality, safety and rail safety objectives. The
Project Engineers are accountable to the Project Manager. The Project Engineers responsibilities
are detailed in the following table:
Area
Requirements of relevant legislations and codes of practise are

implemented throughout the project site when directed by the Project
Manager
Plan, manage and control project activities to assist the construction works
Manage staff to achieve a team environment to meet project objectives

and the objectives of the project manager
Manage sub-contractors to achieve project objectives including material

supply, material recovery, structures and earthworks
Manage the project quality system to ensure contractual obligations are

met
Monitor material stockpile levels to ensure no delays to the program
Regular reporting to the project manager on progress and any issues

which may impact on safety or quality
Update construction program
Provide assistance to project staff in planning, programming and

administration
Procure and expedite materials necessary to perform the works (within

expenditure limits) with no delays to program
Manage plant and labour, in conjunction with supervisors
Appropriate construction methodology and programming options are

explored and are practical, timely and cost effective
All temporary works are designed, verified, documented, fabricated,

installed and safely used in accordance with all method statements and
project procedures within Downers Integrated Management System (IMS)
Identify and investigate project specific engineering advantages

Work collaboratively with the Project Manager, Construction Manager

and Foremen to deliver the project works

General
Communication
Zero Harm
(Safety &
Environment)
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Construction Manager
The Construction Manager is directly responsible for the site operations and the implementation of
all relevant site procedures. The Construction Manager is responsible for ensuring all safety,
quality, environmental procedures are followed in relation to the execution of the works.
The Construction Manager is accountable to the Project Manager. The Construction Managers
responsibilities are detailed in the following table:
Area
General
Communication
Zero Harm
(Safety &
Environment)
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Lead and direct the entire construction team;
Plan, coordinate and monitor the construction activities across the project
against project objectives
Progress procurement of key materials, subcontractors and resources
Manage resources across the project
Work is completed as per Contract Gosford Passing Loops GPL-01-D&C
Hold points are signed off on after completion of relevant task
Client CARs/ Non-Conformances are actioned promptly
Implement requirements of relevant legislation and codes of practice
Document and implement systems of work in accordance with statutory

obligations and the IMS
Oversee sub contractors performance of all work in accordance with

statutory obligations and the IMS
Liaise with the Safety, Environment & Quality Manager on any unique activities that
may require special operating standards or supervision

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Supervisors and Foremen
The Supervisors and Foremen are directly responsible for the day to day operations and the
implementation of all relevant site procedures, and that project operations comply with relevant
statutory obligations.
The Foreman is accountable to the Construction Manager. The Supervisors and Formans
responsibilities are detailed in the following table.
Area
General
Communication
Zero Harm
(Safety &
Environment)
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Implement the requirements of relevant legislations and codes of practise
All work is completed to GPL-01-D&C Contract, ensuring that work is

signed off
All employees and subcontractors are inducted using the Induction

Handbook and in accordance with DA-ZH-PR003 Training and
Competency Management
All visitors onsite are inducted and registered and shall be accompanied
at all time while on site
Introduce new employees to project work standards before they

commence work
Provide clear job instruction and methods to personnel for all tasks
performed
Tasks are performed according to the stipulated Technical Procedures,

other process documents
Client CARs/ Non-Conformances are implemented promptly
Continually observe the process of work for sub standard

practices/methods, reinforcing the required standard of practice

Any relevant bulletin or information pertaining is distributed
Advising personnel of required standards of work, new or amended work

practices that are introduced and hazards associated with specific types
of work.

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Safety, Environment, Quality Manager (SEQM)
The SEQM is responsible for the monitoring and review of the effectiveness of the safety,
environmental and quality controls during the conduct of the contract. Specifically the SEQM has
the responsibilities detailed below.
Area
Safety, Quality
and
Environment
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Provide technical advice and support to the project manager in the

establishment of safety, quality and environmental objectives, targets and
strategies for the project
Facilitate the reporting of project safety, quality and environmental

performance, including trends analysis of lag and lead indicators
Provide technical advice and support in the identification, assessment

and control of workplace risks, SWMS, including purchasing decisions and
plant modifications
Monitor and communicate legislative changes and best practice

initiatives to management and employees
Advise on project compliance with legislation and the Downer Australia

IMS
Establish and implement internal safety, quality and environmental

auditing programs for the project including the development of
subsequent action plans to address identified deficiencies
Assist the project manager in the identification, development and

implementation of safety, quality and environmental training programs for
project employees and management
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11 PROJECT ADMINISTRATION
11.1 PROJECT FILING AND STORAGE SYSTEM
Refer to the Quality Document Control section of the QMP for information on electronic and
hard copy document storage and the nominated quality database
11.2 PROJECT MEETINGS, REVIEWS AND REPORTS
Project and subcontractor meetings will be held weekly on site and will be documented
according to Downer Project Management procedures.
Internal project meetings will be conducted on an as needs basis and minutes of those meetings
recorded and filed in accordance with DA-QA-PR001 Document Management.
The Weekly and Monthly will be prepared as per procedure DA-PM-PR020 Monthly Project
Reporting and Review and as stipulated in the Contract.
11.3 CONSTRUCTION PROGRAMME
The construction program will be handled according to procedure DA-PM-PR011 Project
Management Plans. Refer to the CSMP for further information on the management of the
Program. The program will be submitted as part of the monthly report.
11.4 CONTROL OF DRAWINGS AND SPECIFICATIONS
Refer to the Design Management Plan developed to meet the requirements of contract and TSR
T1 Technical Requirements.
11.5 MANAGING VARIATIONS
Contract variations will be managed according to procedure DA-PM-PR025 Managing Variations,
Delays and Disputes, and in accordance with the contract terms and conditions. No variations
will be implemented without written client approval or direction.
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 26

Revision A
12 INTERNAL AUDITS AND PLANNED INSPECTIONS

12.1 PROJECT AUDITS
Project Audits are planned by the Project Manager in consultation with the Quality Manager and
completed according to procedure DA-QA-PR007 Internal Audits. This will ensure the ongoing
effectiveness of the system and to facilitate continuous improvement.
Audit Reports are available for review on request by the Client and will include the following types
of Audit:
1/ audits of the operation or the quality management system to evaluate its effectiveness as
applied to the project
2/ Project and service audits to assess the conformity of the project or service with the specified
requirements; and
3/ audits of work process control, to evaluate how effectively work process controls are
implemented in practice
(Taken from TfNSW Standard Requirements TSR Q1 Quality Management)
Audits will be continually evaluated and the scope of the activities and products to be audited
adjusted based on the performance of the activities. Frequency and areas targeted for audit will
then be relevant to the performance and activities undertaken.
The Principal may request the opportunity to audit to ensure compliance with the Contract
requirements.
The Principal may request access to audit documentation, records and applicable personnel. All
materials, records and personnel will be made available by Downer.
The internal audit and planned inspection register will be included as an Appendix to this plan
once completed.
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 27

Revision A
13 PURCHASING
Downer as the main contractor will manage all of the operating areas of the project and
subcontractors.
Downer will ensure that all relevant procurement processes (as outlined within Downers IMS
System) will be followed so that subcontractors are selected and appointed to deliver their
relevant scope of works and services in accordance with the contract.
Refer to the Contract Management Plan that stipulates that the requirements of the head
contract will be reflected in the subcontracts and will also ensure that these are also passed
down to lower tier subcontractors. The Contract Management Plan also provides a figure that
diagrammatically shows the hierarchy of contracts developed for the establishment of the
project.
13.1 SUPPLIERS AND SUBCONTRACTORS
Approved key subcontractors at the time of issue of the QMP are noted in the following table.
Subcontractor / Supplier Name
Scope
SMEC
Civil, structures and track design
Robson Civil Projects
Construction of earthworks, culverts, retaining walls and

bridges
WS Atkins International
Safety Assurance
Degotardi, Smith and Partners
DSS survey
DA-ZH-022 Visitor & Contractor Management is applied to ensure that all subcontractors perform
their duties to the required specified requirements for the duration of the project. The following
specific controls apply:
Assessment of subcontractors including past performance
Use of purchase orders and plant-hire/sub-contract agreements
Supervision and continuous monitoring of operations on site
Use of ITPs
Implementation of Downer management processes, Critical Risk Controls and other
process controls over work practices to ensure that subcontractor work is completed
safely and to specification.
All subcontractors are engaged and work on site under the Authority to Work Permit (ATWP)
system, as detailed in DA-ZH-022 Visitor & Contractor Management. A valid work permit is required
prior to a subcontractor undertaking any work on a Downer site.
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 28

Revision A
Subcontractors engaged on the project are allowed to operate under the Downer IMS. However,
Subcontractors can work under their own safety system also, provided the system and
documents, such as Safe Work Method Statements, are to the satisfaction of Project Manager.
Subcontractors will make available (given reasonable notice) all relevant documents and records
as required for auditing purposes.
13.2 SITE INDUCTION AND TRAINING
Site induction and training of all personnel including subcontractors must be completed prior to
undertaking work including:
Project specific induction
Task/work area induction
Daily pre-start, pre-work briefings and visitor induction
Off-site office induction
13.3 PLANT AND EQUIPMENT

All plant and equipment used on site complies with applicable Regulations, and is subject to
regular maintenance per manufacturers specifications and used in accordance with MS024
Vehicle & Mobile Plant.
Downer will control delivery schedules in order to minimise long term storage of products on site.
Specifically Downer will ensure minimum holding and storage times for products and materials
that are hazardous, flammable, sensitive to deterioration, easily damaged, and other causes of
loss. Refer to the CSMP that addresses the transportation and handling of materials.
All internal Plant Risk assessments will be completed on all plant in accordance with DA-ZH-PR028
Zero Harm Risk Management and regulatory requirements.
As stipulated within TfNSW Standard Requirements (TSR Q1 Quality Management), proposed
product substitution under the Contract is at the sole discretion of the Principals representative.
Operation of plant and competency of plant operators, including subcontractor and hired plant
is addressed via:
DA-ZH-PR003 Training and Competency Management
DA-ZH-PR022 Visitor & Contractor Management
MS024 Vehicles & Mobile Plant
MS025 Fixed Plant & Powered Hand Tools
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 29

Revision A
14 PRODUCT AND SERVICE CONTROL

14.1 PROJECT CONTROL DOCUMENTATION
The CSMP provides a high level understanding of Downers approach to delivering the works.
The CSMP also provides an overview of Construction Method Statements (CMS) that define the
approach to procurement and delivering the works in a specific discipline (work area). The CMS
describe the approach to delivering that discipline (work area) with respect to scope, method,
risk, constraints and interface with other disciplines.
Each CMS will be supported by a Site Safety Plan, a Construction Environmental Management
Impact Plan, a Traffic Control Plan and one or more work packages including applicable work
method statements, Lot checklists and ITPs.
The CSMP also provides a figure that diagrammatically shows the hierarchy of management
plans, sub plans, statements and other documentation used to manage and all contractor
activities under the contract.
14.2 PRODUCT IDENTIFICATION AND TRACEABILITY
OP 21 Construction Materials Receiving, Storing and Traceability shall be extended for use in
compliance checking of purchased and client supplied works, products and materials.
14.2.1 Identification
The Project Manager will sub-divide the whole of the work into work packages, establish a lot
identification system and identify each lot on the Lot Register, as prescribed under OP19 Planning
and Checking Construction Work.
14.2.2 Traceability
Traceability of materials will be recorded in accordance with OP21 Construction Materials
Receiving, Storage and Traceability. Furthermore, the Project Manager or nominated
representative will ensure that those measures prescribed under OP21 Construction Materials
Receiving, Storage and Traceability, meet those requirements specified under the contract
agreement.
14.3 HANDLING AND STORAGE OF CONSTRUCTION MATERIALS
Refer to the Construction and Site Management Plan (CSMP) that addresses the transportation
and handling of materials.
14.4 INSPECTION AND TEST EQUIPMENT
All inspection, measuring and testing equipment will be controlled as per procedure DA-QAPR008 Inspection, Measuring & Test Equipment. In the event that inspection, measuring or testing is
proposed via means of a secondary subcontractor, Downer Australia will maintain copies of
calibration records for all subcontractors in accordance with the above procedure.
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 30

Revision A
All Inspection & Test equipment used on site is subject to regular maintenance and is calibrated
as per procedure DA-QA-PR008 Inspection, Measuring & Test Equipment.
Identified Inspection & Test equipment will be recorded in the Calibrated Equipment Register.
Testing of Materials
An accredited NATA laboratory shall conduct testing of materials and samples where required
using approved NATA testing processes.
14.5 CONTROL OF NON-CONFORMING MATERIALS OR WORK
Non-conforming materials or work will be recorded on Non-conformance Reports and handled as
per OP20 Handling Non-Conforming Materials or Work. A Non-conformance Register will be
established by the Project Manager, which will be used to identify the status of each Nonconformance report.
The Project Manager will obtain the clients written approval for proposed repairs, rework or
concessions in accordance with the requirements of the Clients Quality Assurance
Requirements. The Clients approval will be obtained prior to the implementation of the Downers
proposal.
14.6 DESIGN CONTROL
The Project Design Management Plan (DMP) defines project overview, design strategic
objectives, design processes and procedures of managing delivery of design for all design
packages. The DMP has been developed to meet the specific requirements of the Project. The
DMP represents the overarching management plan for control of design and will be used to
guide and inform the development of the individual design consultant management plans in the
delivery phase. For further information regarding Design Management, refer to the Design
Management Plan developed to meet the requirements of contract and TSR T1 Technical
Requirements.
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 31

Revision A
15 INSPECTION AND TESTING

15.1 ITP COMPLIANCE
All quality related construction activities shall be managed by Downer using ITPs and associated
Lot Checklists developed by the Engineering Team and Project Manager.
Downer will prepare, maintain and update ITPs in accordance with TfNSW Inspection and Test
Plans Minimum Requirements 4TP-ST-068.
15.2 CONTROL AND STORAGE OF ITPS
All ITPs and supporting information and evidence will be recorded and stored in the Quality
Database QAntrol.
Hard Copies ITPs will be stored as outlined within the Quality Document Control section of this
plan.
15.3 MANAGEMENT OF ITPS
ITPs will be managed by the Project Team (Engineering Managers, Design Manager and Project
Manager) in consultation with the Quality Manager. The requirements for the ITPs will be
determined by the applicable Engineering Manager, and all ITPs developed by subcontractors
for their portion of the work will be reviewed and approved by the applicable Engineering
Manager or his delegate.
15.4 PRINCIPAL ITP REQUIREMENTS
The Principal may provide specific requirements and inspection and testing regimes for inclusion
within the ITPs. These requirements will be incorporated into the ITPs. This will ensure that ITPs
include acceptance criteria and design intent prior to submission to the Principals Representative
for review as set out in the contract.
15.5 DEVELOPMENT OF ITPS
The following process will be used to review and approve ITPs:
1.
Applicable Engineering Manager prepares ITP based on requirements and

specifications and submits to Design Manager for review
2.
Design Manager reviews ITP and either sends back to Engineering Manager with
changes or approves
3.
Design Manager submits ITP to Project Manager for review and approval. Project
Manager either makes changes or provides approval ensuring that it satisfies all
relevant standards and specifications for the proposed works
4.
Once approved, the Project Manager will then submit to the Quality Manager
5.
Quality Manager will submit to Principal for review and approval
6.
Once approved, the Quality Manager will enter the ITP into QAntrol
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 32

Revision A
7.
The ITP will then be undertaken by the engineer responsible for the work or the
approved representative and entered into QAntrol.
15.6 MANAGEMENT OF ITPS AND LOT CHECKLISTS

Lot checklists (for each Lot created under the ITP code) will be generated from QAntrol by the
Engineering Manager responsible for that work. The lot checklist will be provided to the Supervisor
or Foreman to confirm compliance. The responsible Engineering Manager will also be responsible
for progressive inspection and audit of site works to ensure conformance.
Lot Checklists document:
notification timeframes
release of witness and hold points
evidence of site inspections
the verification of recorded information
15.7 HOLD POINTS AND WITNESS POINTS

Compliance with critical aspects of the project is addressed via the use of nominated Hold Points
and Witness Points.
Planned Hold Points and Witness Points form part of the individual Work Instructions and ITPs and
are approved by the Engineering Manager, Design Manager, Project Manager and by the
Principals Representative.
TfNSW Standard Requirements TSR Q1 Quality Management Appendix A5 lists the Principals
nominated Hold Points and Witness Points. Details of these Hold Points and Witness Points will be
included within the applicable ITPs, as well as the specific process to be held and/or witnessed,
submission requirements and the process of approval by the Principal.
The Engineering Manager / Site Supervisor is responsible for advising the Principals Representative
that a Witness Point or Hold Point is due for inspection.
Notifications of Hold Points and Witness Points will be included within the Lot Checklists and
completed ITPs and Lot Checklists recorded within QAntrol.
15.8 NON-CONFORMANCES
All non-conforming materials or work will be managed in accordance with the contract
requirements and DA-QA-PR005 Corrective and Preventive Action.
Note: Non-conformances automatically create a Hold Point.
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 33

Revision A
16 CLEANING AND PROTECTION OF WORK

Downer will ensure that all works and temporary works on site will remain clean and protected for
the duration of the contract. This will include:
protection of newly installed works to ensure no damage or deterioration

cleaning and maintaining newly installed works as frequently as required according to
the manufacturers specifications
cleaning and rectification of any works soiled, marred or damaged.

Downer will also ensure final cleaning of building works prior to completion to the satisfaction of
TfNSW Standard Requirements (TSR Q1 Quality Management).
Please refer to the CSMP for further information on Cleaning and Protection of Site Work.
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 34

Revision A
APPENDIX A: IMS ACCREDITATION CERTIFICATES
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 35

Revision A
Appendix B: DOWNER AUSTRALIA BUSINESS POLICY
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 36

Revision A
Appendix C: HOLD AND WITNESS POINT REGISTER

This is currently under development
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 37

Revision A
Appendix D: AUDIT AND REVIEW SCHEDULE

This is currently under development.
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 38

Revision A
Appendix E: INDEX OF QUALITY PROCEDURES AND FORMS

Note: Downer Australia is currently rolling out updated business processes (to form a new Downer
Australia IMS). Consequently as new Downer Australia forms and procedures become available
they will replace the existing Downer EDI equivalents.
QUALITY MANAGEMENT - PROCEDURES
DA-QA-PR001
Document Management
DA-QA-PR002
Downer Australia Document Implementation
DA-QA-PR003
Business Planning, Objectives and Targets
DA-QA-PR004
Management Review
DA-QA-PR005
Non Conformance, Corrective and Preventative Action
DA-QA-PR006
Inspection & Testing
DA-QA-PR007
Internal Audit
DA-QA-PR008
Inspection, Measure and Test Equipment
DA-QA-PR009
Records Management
QUALITY MANAGEMENT - FORMS

DA-QA-FM001.1
Document distribution register
DA-QA-FM001.2
Authority to release to document centre
DA-QA-FM001.3
Management Procedure template
DA-QA-FM001.4
Work Instruction template
DA-QA-FM001.5
Form template
DA-QA-FM001.6
Document numbering convention
DA-QA-FM001.7
Flowchart template portrait
DA-QA-FM001.8
Flowchart template landscape
DA-QA-FM001.9
Document review template
DA-QA-FM003.1
Downer Australia bluesheet template
DA-QA-FM003.2
Objectives and targets register
DA-QA-FM003.3
Plans Objectives and Targets review checklist
DA-QA-FM004.1
Management review agenda and minutes
DA-QA-FM005.1
Corrective Action Report
DA-QA-FM005.2
CAR Register
DA-QA-FM007.2
Internal Audit register
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 39

Revision A
QUALITY MANAGEMENT - FORMS

DA-QA-FM007.3
Internal Audit schedule
DA-QA-FM007.4
Relationship of IMS to AS/ISO standards
DA-QA-FM007.5
Audit checklist template
DA-QA-FM008.1
Test Equipment Register
DA-QA-FM009.1
Archive Register
DA-QA-FM009.2
Archive Register
DA-QA-FM009.3
Destruction Authority
Downer EDI Limited

ABN 66 008 709 608
www.downergroup.com
Page 40

Quality Plan Gosford Passing Loops Project

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Quality Management Plan

Quality Management Plan

Document Preparation & Control

Elisha Howells Quality Officer

Sheree Jones Quality Manager GPL

David Burkitt Project Director

Downer EDI Limited

Quality Management Plan

Downer EDI Limited

Quality Management Plan

Downer EDI Limited

Quality Management Plan

TERMS AND DEFINITIONS

Acronym for Corrective Action Request (CAR) is raised when a process or

Acronym for Construction Environmental Management Plan

Acronym for Community Liaison Plan

Acronym for Conditions of approval

Verification of how implementation is proceeding with respect to a

Acronym for Construction and Site Management Plan

Document code for Downer Australia Quality Management Form

Document code for Downer Australia Quality Management Procedure

Document code for Downer Australia Quality Management Register

Document code for Downer Australia Quality Management Record

Document code for Downer Australia Quality Management Training

Director-General of the NSW Department of Planning and Infrastructure (or

Acronym for Design Management Plan

Acronym for Department of Planning and Infrastructure

Acronym for Emergency Management Plan

Acronym for Gosford City Council

Downer EDI Limited

Quality Management Plan

Acronym for Integrated Management System

Checklist to record performance and outcomes of project inspections and

Acronym for Inspection and Test Plan.

Failure to comply with the requirements of the Project approval or any

Failure to conform to the requirements of Project system documentation

Acronym for Northern Sydney Freight Corridor

Acronym for Non Conformance Report

A document setting out the specific practices, resources, activities and

The Project Principal Transport for NSW

The Gosford Passing Loops Project

Acronym for Quality Assurance. It refers to the planned and systematic

Acronym for Quality Management Plan

Acronym for Review of Environmental Factors, environmental assessment

Key Project Stakeholders.

Acronym for Safe Work Method Statement

Acronym for Transport for NSW

Downer EDI Limited

Quality Management Plan

Downer EDI Limited

Quality Management Plan

2 PURPOSE OF THE QUALITY MANAGEMENT PLAN (QMP)

Downer EDI Limited

Quality Management Plan

OPERATIONAL PROJECT PURPOSE

Downer EDI Limited

Quality Management Plan

Downer EDI Limited

Quality Management Plan

Downer EDI Limited

Quality Management Plan

Figure 1 Project Overview